Title: Quality and productivity improvement through spot welding process optimisation in automobile body shop

Authors: G. Selvam; S. Arockia Doss Prince; V. Surya Prakash; T. Rohit

Addresses: Department of Mechanical Engineering, B.S. Abdur Rahman University, Vandalur, Chennai, Tamil Nadu 600048, India; Central Manufacturing Engineering, Mahindra & Mahindra Ltd, Mahindra Research Valley, Mahindra World City, Anjur P.O., Chengalpattu, Tamil Nadu 603204, India ' Department of Mechanical Engineering, B.S. Abdur Rahman University, Vandalur, Chennai, Tamil Nadu 600048, India ' Mahindra & Mahindra Ltd., Mahindra Research Valley, Mahindra World City, Anjur P.O., Chengalpattu, Tamil Nadu 603204, India ' Mahindra & Mahindra Ltd., Plant 1, Nashik, Maharashtra 422007, India

Abstract: Optimised geometry weld spot distribution for different configurations of automobile body sub-assemblies, is a critical activity in any automobile body shop process planning. For an ideal body shop planning, it has to be planned in a systematic approach so that the maximum productivity with high quality is being achieved. For this, the optimised planning has to be made for number of spots welded in a geometry station. The lesser the number of spots, the higher will be the dimensional variations of the assembly; the greater the number of spots, the lesser will be the productivity of the sub-assembly lines. The aim of this paper is to identify an optimised spot quantity for different sizes of parts with different surface contacts. To identify the optimum spot quantity, an industrial experiment was conducted using Taguchi method (L27 OA). Dimensional variations of the samples were recorded in two stages: 1) post-geometry spot welding; 2) post re-spot welding; and the measured data was thoroughly analysed. Recommendations for the optimised number of spots for geometry spot weld stage were made for different assembly configurations. These recommendations are discussed in detail. This study will aid the process planners to distribute the appropriate number of spots in the geometry welding stations.

Keywords: body-in-white; BIW; productivity; quality; geometry spot; re spot; Taguchi method; DOE; process optimisation; body shop; weld shop; surface contact; dimensional stability.

DOI: 10.1504/IJPQM.2018.088611

International Journal of Productivity and Quality Management, 2018 Vol.23 No.1, pp.110 - 127

Received: 23 Aug 2016
Accepted: 25 Nov 2016
Published online: 13 Dec 2017 *

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