IMPLANT TRAINING REPORT

GENRAL MOTORS PVT. LTD.

CUSROW WADIA INSTITUTE OF TECHNOLOGY,
PUNE – 411001

Department of Mechanical Engineering

“Implant Training Report on”

Company Name: GENRAL MOTORS.

Shop: POWERTRAIN SHOP.

Duration
01/06/2020 to 30/06/2020.

Candidate Name: BUTLA PRANAV SHRINIVAS

Enrollment No: 192186.

Prof. Gavali S. L. Prof. Kamble U. N.

(Mentor) (HOD)
 Table of Contents
History ............................................................................................................................................................................... 1
About Plant........................................................................................................................................................................ 2
Keywords. ...................................................................................................................................................................... 2
General Motors’ key brands ......................................................................................................................................... 2
Cadillac Brand. ............................................................................................................................................................... 3
Buick brand.................................................................................................................................................................... 3
GMC brand. ................................................................................................................................................................... 4
Opel................................................................................................................................................................................ 4
Mission/Vision Statement ................................................................................................................................................ 5
Company Values ............................................................................................................................................................ 5
Mission/Vision............................................................................................................................................................... 5
Products Manufactured ....................................................................................................................................................... 6
Work Organization in the Plant ........................................................................................................................................ 7
Labor Hours ................................................................................................................................................................... 8
Automobile Final Assembly Plant..................................................................................................................................... 9
Number of Workstations in the Final Assembly Plant ................................................................................................. 9
Material Handling System............................................................................................................................................. 9
BODY SHOP. .....................................................................................................................................................................10
The Paint Shop.................................................................................................................................................................12
GENERAL ASSEMBLY SHOP .............................................................................................................................................14
Trim-Chassis-Final .......................................................................................................................................................14
Reprocess Department ...............................................................................................................................................14
POWERTRAIN SHOP ........................................................................................................................................................15
About Powertrain Department...................................................................................................................................15
Machine Shop ..............................................................................................................................................................15
Engine Assembly Shop ................................................................................................................................................15
Engine Assembly Line ..................................................................................................................................................16
Leak and Cold Test.......................................................................................................................................................16
Hot Test. ......................................................................................................................................................................17
Final inspection (Quality checkup’s) ...........................................................................................................................18
Types of engine made by GENRAL MOTOR’S .................................................................................................................19
Automotive gasoline engines .....................................................................................................................................20
Two-cylinder ............................................................................................................................................................20
Three-cylinder .........................................................................................................................................................20
Inline-3 .....................................................................................................................................................................20
Four-cylinder ...........................................................................................................................................................21
Inline-8 .....................................................................................................................................................................24
 Automotive diesel engines .........................................................................................................................................25
Three-cylinder .........................................................................................................................................................25
Four-cylinder ...........................................................................................................................................................25
Six-cylinder ..............................................................................................................................................................25
Eight-cylinder...........................................................................................................................................................25
Other diesel engines ...................................................................................................................................................26
Locomotive engines ....................................................................................................................................................26
Marine/stationary diesel engines ..............................................................................................................................26
Aircraft engines ...........................................................................................................................................................27
Propfan ....................................................................................................................................................................27
Turboprop ................................................................................................................................................................27
Turboshaft ...............................................................................................................................................................27
GM Medium Diesel engine .............................................................................................................................................28
Machine and Equipment Used .......................................................................................................................................30
Automatic CNC Block Blueprinting: CNC Probing ......................................................................................................30
CNC Engine Block surfacing.........................................................................................................................................31
CNC Engine Block Boring .............................................................................................................................................31
Head Stud conversion, automatic, drill, counter bore and tap... just takes minutes. .............................................32
CNC Lifter Bore Machining ..........................................................................................................................................32
CNC Spot Facing ...........................................................................................................................................................33
4 bolt Main Bearing Cap Conversion ..........................................................................................................................33
O-ring Grooving ...........................................................................................................................................................33
Cylinder Chamfering....................................................................................................................................................34
CNC Block Lightening...................................................................................................................................................34
Threadmilling freeze plug holes. (and other threads) ...............................................................................................34
Cylinder Head surfacing! Acheive incredible Ra's ......................................................................................................35
Stroker crank clearance machining. ...........................................................................................................................35
CNC Engine Block Engraving .......................................................................................................................................35
Office Space .....................................................................................................................................................................36
Aisle, Dock, and Storage Space .......................................................................................................................................36
Conclusions ......................................................................................................................................................................36
Here are some ‘videos links' of how industry work. ..................................................................................................36
 Page |1

General Motors Talegaon Plant

History

General Motors began doing business in India in 1928, assembling Chevrolet cars, trucks and buses,
but ceased its assembly operations in 1954. GM continued with tie-ups with Hindustan Motors to
build Bedford trucks, Vauxhall cars, Allison Transmissions and off-road equipment.
In 1994, GMIPL was formed as a joint venture, owned 50 percent by Hindustan Motors and 50 percent
by General Motors, to produce and sell Opel branded vehicles. GM bought out the Hindustan Motors
interest in 1999. GMIPL continued to produce Opel cars at the Halol facility until 2003, when it started
production of Chevrolet vehicles at that location.
In 2000, GMIPL moved its headquarters to Gurgaon. In 2003, the company opened its technical center
operations in Bangalore, which included research and development and vehicle engineering activities. The
technical center operations were expanded to include purchasing and financial support services for General
Motors operations located outside of India (2006), vehicle engine and transmission design and engineering
(2007) and a vehicle design studio (2007).

GMIPL began construction of a second vehicle assembly plant in Talegaon in 2006, which began
production of Chevrolet vehicles in September 2008.

In late 2009, General Motors announced that it would put its India operation into a 50–50 venture with
Shanghai Automotive Industry Corporation of China, which is the partner of GM's main venture in China.
In October 2012, General Motors-Chevrolet announced that it has increased stake in its Indian
subsidiary to 93% by buying 43% from its Chinese partner SAIC for an undisclosed sum.
GMIPL announced in 2017 that by December all the Chevrolet models sold by the company will cease
sales and that they are exiting the Indian market. Chevrolet cars will still be manufactured in Indian plants
for exports.

In January 2020, Chinese automobile manufacturer Great Wall Motors is set to acquire General
Motors’ Talegaon manufacturing plant near Pune.
 Page |2

About Plant.
The Talegaon plant is a General Motors assembly and powertrain production facility located in Talegaon,
Maharashtra, India.
• Address:
MIDC phase 2 expansion
Near floriculture Park
Navlakh Umbre Village Road
Talegaon – 410507, Maharashtra
India

• Annual production capacity:

1. Vehicles: 165,000
2. Powertrain: 160,000

• Number Of Sub-Assembly Shop:

1. BODY SHOP
2. PAINT SHOP
3. GENERAL ASSEMBLY SHOP
4. POWERTRAIN

Keywords.
• Powered conveyor
• Assembly line
• Line balancing
• Equipment selection
• Automotive industry

General Motors’ key brands

Previously, we discussed how Chevrolet brand has played an instrumental role in the success of
General Motors. In this article of the series, we’ll have a look at some other key brands under General
Motors’ (GM) umbrella.
 Page |3

Cadillac Brand.

Cadillac is the most popular luxury car brand in General Motors’ portfolio. This brand was established
in 1902 with the foundation of the Cadillac Automobile Company. Cadillac became a part of GM’s portfolio
in 1909.Cadillac brand cars are known to have been used by US presidents for decades. Currently, the brand
is also playing an important role in expanding GM’s reach in the Chinese market, with high demand from the
region. At present under the Cadillac brand, the company offers the 2016 CT6 Sedan, the 2016 ATS-V Coupe,
the 2016 Escalade, and the 2016 SRX Crossover, among other vehicles.

Buick brand.

Buick is the entry level luxury brand in General Motors’ portfolio. The brand was established in
1899 when David Dunbar Buick founded the Buick Auto-Vim and Power Company.Since the beginning of
General Motors in 1908, Buick has been a significant part of its portfolio. Under this brand, the company
sells many modern luxury sedans and crossovers cars. Currently, the Buick Enclave, Buick Verano, Buick
Regal, and Buick Cascada are some of the key Buick car models offered by GM..Volkswagen’s (VLKAY)
Porsche and Daimler’s (DDAIF) Mercedes can be seen as the competition to General Motors’ vehicles in the
luxury car segment.
 Page |4

GMC brand.

GMC has manufactured trucks since 1902. It later became an integral part of General Motors’ portfolio.
During World War II, GMC produced nearly 600,000 trucks to be used by the US military. Even today, the
brand is well known in the US market in the full-size truck segment

The Chevrolet division of GM was originally founded by William C. Durant in 1911. Back then, the first
big challenge was developing a competitor for Ford’s Model T. The division was later taken over by Louis
Chevrolet.In the U.S., Chevy produces a broad range of quality vehicles from subcompact cars to mid-size
pickup trucks. Chevy is a household name and often used when talking about all GM and its offerings.

Opel

Opel Automobile GmbH (German pronunciation) , usually shortened to Opel, is a German automobile
manufacturer subsidiary of Groupe PSA since August 2017. From 1929 until 2017, Opel was owned
by General Motors. Opel vehicles are sold in the United Kingdom, Isle of Man and Channel Islands under
the Vauxhall brand. Some Opel vehicles were badge-engineered in Australia under the Holden brand until
2020 and in North America and China under the Buick, Saturn, and Cadillac brands.
Opel traces its roots to a sewing machine manufacturer founded by Adam Opel in 1862 in Rüsselsheim
am Main. The company began manufacturing bicycles in 1886 and produced its first automobile in 1899.
After listing on the stock market in 1929, General Motors took a majority stake in Opel and then full control
in 1931, establishing an American ownership of the German automaker for nearly 90 year
 Page |5

Mission/Vision Statement

The mission/vision of GM is to be the world leader in transportation products and related services
(General Motors, 2008b). Through continuous improvements driven by integrity, teamwork, and innovation
of GM people, the company has earned its customers’ trust and enthusiasm. With all of the competition and
the advancement of hybrid and alternative fueled vehicles, GM should look to being a leader of innovation.
With this in mind, the mission statement could read GM will become the world leader in quality, innovative,
and cost efficient products. The mission is for GM to become the auto industry leader in sales and market
share in the global market.

Company Values

GM has six core values in which employees are to use in conducting daily business practices (General
Motors, 2008c). These core values consist of continuous improvement, customer enthusiasm, innovation,
teamwork, and individual respect and responsibility. These values must portray an image to the company’s
consumers that it values their needs and wants. With this said GM should add customer value and thinking
green to its core values. This measure would show the company is focused on achieving high levels of
customer satisfaction by providing innovative products that offer customers more choices with alternative
fueled vehicles. Thinking green will show the company is concerned with doing right by the environment

Mission/Vision

In order for GM to achieve its vision, the company understands that many issues must be addressed in
order to attain its many goals. In order to become a more sustainable company, GM recognizes the
importance of integrating economic, environmental, and social objectives into its daily business objectives
and future planning activities. The future success of the company partly depends on technology, innovation,
and partnerships (General Motors, 2008b).

With technology, GM can efficiently address climate changes and fuel efficiency through its products.
By accelerating the development and deployment of new technology, the company is able to improve its
existing technology. Innovation provides GM with the tools to develop new ways of doing things as a
company and with others. With increased competition in the global industry, innovation is critical in the
future success of the company. In order to continue being responsive to the needs and concerns of its
stakeholder and creating a sustainable future, GM understands the importance of continuing to build strong
partnerships with the employees, industries, governments, markets, and communities, and others in order
to be responsive to the needs and concerns of our various stakeholders (General Motors, 2008b).
 Page |6

Products Manufactured

The Talegaon plant currently assembles the following vehicles for the Indian market:

• Chevrolet Spark (legacy Daewoo Matiz)

• Chevrolet Beat (global-market Chevrolet Spark)
• Chevrolet Sail sedan and Chevrolet Sail hatchback

Later in 2017, the facility added assembly of the following vehicles transferred from the Halol plant:

• Chevrolet Cruze (first generation)

• Chevrolet Enjoy
• Chevrolet Tavera
 Page |7

Work Organization in the Plant

Automobile final assembly plants are usually divided into three major departments: (1) body shop, (2)
paint shop, and (3) trim-chassis-final. This plant will be organized accordingly. The three departments must
all be contained within one building, but the paint shop must be physically separated from the others
because of cleanliness, processing, and ventilation problems associated with spray-painting technology. In
addition, there will be a fourth department, (4) reprocess, to fix those cars needing repair as they exit trim-
chassis-final. Storage buffers with substantial capacities will be installed between the body shop and the
paint shop, and between the paint shop and trim-chassis-final. A summary of the work flow is illustrated in
Figure 1.

Figure 1 - Major departments and work flow in an automobile final assembly plant.

Body Shop Storage Buffer PaintShop Storage Trim- Reprocess

➔ ➔ ➔ Buffer ➔ chassis-final ➔
➔

About a thousand spot-welds are made in the body shop. To begin the assembly, the individual
sheetmetal parts, consisting of the floorpans and side panels, are loosely fastened together by human
workers. The car body then moves through a series of spot-welding operations, both robotic and manual,
to add more parts and permanently assemble the body.

After the sheetmetal body is completed, it then moves into a temporary storage area that serves as a
buffer in case of significant downtime delays in either the body shop or the paint shop that follows. From
the temporary storage area, the car bodies move into the paint shop, where a series of processes are
performed to paint the car body.

The painted car bodies are then transported from the paint shop to another temporary storage area
to permit thorough curing and drying of the paint, and to permit proper sequencing of the components that
will be added in trim-chassis-final. Cars are produced from customer orders with specific combinations of
parts, and the proper parts must arrive at the respective workstations at the same time as the corresponding
car bodies.
The car bodies then move to the trim-chassis-final department, where the remaining parts and
subassemblies are assembled into the body. These include the engine and transmission, dashboard, seats,
tires, and so on. When all of the trim and chassis work have been completed, the cars are ready to be driven
off the line. However, in some cases, there are quality problems that must be repaired on the completed
automobile. This repair is accomplished in the reprocess department, which is located after the end of the
line in trim-chassis-final. It consists of a large open area with stalls in which repairs are made on cars that
have quality problems or missing components. There is no conveyor line in the reprocess department since
even cars needing rework can usually be driven after completion in trim-chassis-final.
 Page |8

Labor Hours
It takes 20 hours of direct labor to complete the average automobile to be assembled in the proposed
plant. The division of labor hours between the three sections of the plant is given inTable 1 - Labor hours
in the four departments of the final assembly plant

Work organization Labor hours

Body Manual assembly; then Robogate, 2.0 hr Minor Department

shop followed by robotic and manual variations Variation in hours
welding stations.

Paint Automated dip tanks, then robotic 3.0 hr No variation

shop and manual stations. Repair loop
after painting

Trim- All manual stations 14.0 hr Range = 12 to

chassis- 16 hours,
final uniform
distribution

Reprocess All direct labor 1.0 hr Range = 0 to 3

hours, normal
distribution
with σ = 0.35
hour

Department Subtotal 20.00 hr

Most of the direct labor is in the trim-chassis-final area. This is typical because the body shop and
paint shop are highly automated; the assembly work in trim-chassis-final is difficult to automate.
Maneuvering back seats into position, and attaching dashboard assemblies, for example, are difficult for a
robot to perform. These operations require a certain sense-of-touch and other skills that only humans
possess.
There will be variations in these labor hour values from car to car because of differences in models
and options. For a plant that produces several different models, some models will require a larger total
direct labor time, others less time. Measures of this variability are provided in Table 1 for each department.
This plant will produce two-door and four-door sedans. The four-door models require more time than the
two-door models. Options have a significant effect on total direct labor time. Cars loaded with options (e.g.,
special radio, air conditioning, moon-roof, etc.) take significantly longer to assemble than cars with the
standard equipment. The labor hour data in Table 1 are intended to represent the expected average
automobile that will be produced in the plant, and these figures should be used for planning purposes.
In addition to direct labor hours, there are also indirect and overhead hours for the plant. The indirect
category includes the foremen and supervisors, maintenance and repair personnel, material handling, and
other support people. Overhead includes plant management and professional personnel (engineering,
accounting, etc.).
 Page |9

Automobile Final Assembly Plant

This case problem deals with the analysis of workstation, material handling, and floor space
requirements for a proposed automobile final assembly plant. The plant will have a product-flow layout,
capable of producing 60 automobiles per hour for 10 hours per day (one 10hour shift, including overtime),
five days per week (a total of 150,000 cars per year). Only assembly will be done in the plant - no parts
manufacturing. All components will be delivered from outside suppliers. The plant will be built as a one-
story structure, including office space for management, technical, and other staff.

Number of Workstations in the Final Assembly Plant

The total direct labor hours must be allocated among workstations located along the line of flow of
the cars moving through the factory. With a production rate of 60 cars per hour or one car per minute, this
means that the work accomplished at each station must be completed in one minute or less. (The cycle time
is the reciprocal of the production rate.) The total number of workstations in the plant will be influenced by
certain factors and by differences in the work performed in the three sections. The following factors must
be taken into account in the planning and design computations
• Line balancing - It is impossible to allocate exactly one minute of work to each station,
because of variations in work element times at the different workstations. Some workers will have work
requiring less than one minute. In addition, different automobile models require different total times,
and this aggravates the line balancing problem. Options on the cars (air conditioners, special radios,
sunroofs, etc.) also complicate the line balancing problem. Balance delay values are given for each of
the three major departments.

• Manning levels - In most cases, more than one worker can be assigned to each station where
manual assembly operations are performed. For example, one worker might be performing an
operation on one side of the car, while another worker is doing similar work on the opposite side. This
reduces the number of manual workstations required on the line. Manning levels are presented for
each department.

• Level of automation - Some workstations are automated using industrial robots and other
automated machines. These stations do not add direct labor hours to the car, but they add to the
number of workstations on the line. The automated stations are more numerous in the body shop and
paint shop than in trim-chassis-final. Details are given for each department in which automation is a
factor in the planning process.

• Delay sections - Some additional stations and sections of conveyor must be allocated to
accommodate special (non-workstation) sections of the line such as drying ovens, inventory banks,
switches in the conveyor system, and so forth. These stations do not have workers assigned to them.
The needs for these areas are described in the case problem. Switches in the conveyor system might be
used, for example, to provide repair loops in the regular line.
 P a g e | 10

Material Handling System

Various types of material transport equipment will be used in different sections of the plant. Some
areas require continuously moving transport, while others require synchronous transport (also called
intermittent transport). For example, continuous transport is required in the trim-chassis-final area, while
synchronous transport is required for accurate location in the spotwelding line. Also, there will be some
portions of the flow path that are overhead, while other portions are on-the-floor. The overhead portions
may be used for in-process storage and movement between the three plant sections. These different
material handling systems must be integrated so as to achieve smooth flow of the product from one section
of the plant to the next.

Throughout the plant, the car bodies are moved on work carriers. Standard work carriers have been
designed to hold the different body styles. All of the transport systems (intermittent and continuous,
overhead and on-the-floor) can accommodate the standard work carrier, up to the location in trim-chassis-
final where the wheels are added to the car. At this point the cars are removed from the work carriers, and
a chain-in-floor conveyor system is used to move the cars from this point to the end of the assembly line.
The chain-in-floor system does not utilize work carriers. Instead, the cars roll on their own wheels. The
wheels are added to the car approximately 10 workstations from the end of the line.
A special overhead conveyor system must be provided to move the standard work carriers back to the
beginning of the body shop line so that they can be re-used. This conveyor length should not be included in
the total flow path length, because the return conveyor length depends on the shape of the plant and where
the starting points and ending points of the flow path are located.
The work carriers are 20 ft long and must be separated in their movement on the conveyor system by
a distance of 5 ft. The cars themselves are each 16 ft long, and they must be separated by 9 ft. The car
bodies are each 6 ft wide, and the work carriers are the same width.
Storage buffers are included at various locations in the sequence of work flow. They provide the
automobile assembly plant with a way of dealing with a number of production problems that occur in final
assembly. The following paragraphs describe the uses of these storage areas. Storage buffers should be
included in the analysis, and space allocated accordingly. The following descriptions indicate their locations.

• Storage buffers must be located after automated sections of the welding line in the body
shop, so that if one section breaks down, the upstream and/or downstream sections of the line can
continue to operate. Details on the requirements of these storage areas are presented in the description
of the body shop.

• Car bodies going from the body shop to the paint shop will have a 3/4-hour delay, in case of
large downtimes in either the body shop or the paint shop.

• Painted car bodies going from the paint shop to trim-chassis-final will have a 3.5-hour delay.
This is required to permit components and subassemblies in trim-chassis-final to be sequenced to be
consistent with the car body sequence. Most of the items added in trim-chassis-final are shipped by
suppliers near the plant according to a just-in-time discipline. The delay between paint shop and trim-
chassis-final allows time for the plant inventory control personnel to organize the components (motors,
dashboards, seats, etc.) for feeding to the appropriate stations in a sequence that agrees with the arrival
of car bodies down the line.
 P a g e | 11

BODY SHOP.

Nearly all of the sheetmetal body components in an automobile body are assembled by spot welding.
There are approximately 4000 spot-welds on a typical car, about 1000 of which are accomplished in the
body shop. The very first operations consist of manually fastening the side panels and floorpan together to
form the initial body assembly. This is called "toy tabbing" because the fastening is accomplished by bending
metal tabs on the sheetmetal parts. Each car body is then fed through a framing system which fixtures the
body and performs a limited number of spot welds to hold the subassembly into this alignment. From the
framing system the car bodies are transferred through a series of robotic stations which accomplish
additional spot-welds. At subsequent stations in the body shop, the roof, hood, and other sheetmetal parts
are added and spot-welded in place to complete the car body. To repair any blemishes, scratches, and rough
spots, the bodies then move through a metal finishing section of the line where workers grind and wire-
brush the imperfections out and smooth the sheetmetal surfaces.

The body shop is a highly automated department, the automation consisting of robotic spot welding
stations at which approximately 800 of the 1000 spot welds in the body shop are performed. An overview
of the work flow in the body shop is provided in Figure 2.
Figure 2 - Work flow in the body shop.

Toy tab Robo gate Buffer Manuel Respot Buffer Manuel

➔ ➔ ➔ ➔ ➔ ➔ ➔
The assembly process begins with body side panels and floorpans being launched onto the front of
the conveyor line. Toy tabbing is performed at five manual workstations to fasten together the body panels
before they move into the framing system.
The framing system, called "Robogate", is 100 ft long and 30 ft wide. Robots and other automated
devices are used to accomplish the initial spot welds to make the car body rigid. A total of 200 spot welds
are performed in the Robogate. A crew of six workers attends to the Robogate, providing supplies,
reprogramming if necessary, and performing maintenance and repairs as necessary. The cycle time of the
Robogate is well within the required 1.0 min. production time requirement, even considering occasional
downtime. The Robogate is followed by a storage buffer with capacity of 12 car bodies. This is considered
sufficient to maintain an overall production rate at 60 units/hour.Next in the sequence are ten manual
stations which add the remaining parts (roof, trunk, lid, etc.) except doors. No welding is performed at these
stations.
 P a g e | 12

The ten manual stations are followed by an automated line consisting exclusively of spot welding
robots; it is called the "respot" line. The respot line requires a crew of 12 workers to perform maintenance
and repairs when breakdowns occur and to otherwise tend the line. The number of robotic welding stations
on the line must be determined from the following. A total of 640 spot welds must be accomplished. Each
station will have two robots, one on either side of the line. Repositioning time for each robot Tr = 9 sec. This
is equal to the transfer time of the material handling system moving the car bodies between stations. Each
robot must be programmed to perform a certain number of spot welds s. The value of s will be nearly the
same for each robot. It takes 2 sec for the robot to perform each weld during its service time; thus, T s = 2s,
and Tc = 9 + 2s. For each station, frequency of failure = 0.0025 (1 breakdown every 400 cycles). A failure
stops the line, and average downtime per occurrence = 5 minutes (300 sec). Based on this data, you must
determine the number of robots required on the line to achieve the specified production rate.

The respot line is followed by a storage buffer with capacity of 12 car bodies, which is considered
sufficient to maintain overall production rate at 60 units/hour.
After the storage buffer following respot, a series of manual workstations are used to assemble the
doors and other fixtures that must be on the car body prior to painting. This section of the line includes
manual spot welding stations that complete 160 spot welds which cannot be accomplished by robots. The
section also includes a metal finish section where the sheet metal is cleaned and repaired using grinding and
wire-brushing. This step prepares the surfaces of the car body for painting. The manning level in the body
shop for all manual stations will average 2.0, the balance delay in this department is expected to be 0.08,
and line efficiency (proportion uptime) in the manual portions of the line = 100%. Repositioning time = 0.15
minute; however, this time is included in the total labor hours for this (and other) departments, so it need
not be considered in the case problem.
Each station in this department is 25 ft in length and 30 ft wide (12 ft on either side of the line, allowing
for the 6 ft width of the car body and carrier. The two storage buffers in this department need be only 12 ft
wide which includes an allowance for safety and maintenance. These buffers are to be on-the-floor
conveyors. Synchronous transport of car bodies must be used at all stations in this department, but not in
the storage buffers. In the buffers, quick access to units in storage is required.
It consists of Press shop, Welding prats and Assembly line. This shop starts the production line in plant
which first start with chesses and then hole body work assembly parts by parts on the moving conveyer.
After assembly of all parts the vehicle exits the body shop. And the same conveyer moves to Paint shop.
This step prepares the surfaces of the car body for painting. The manning level in the body shop for
all manual stations will average 2.0, the balance delay in this department is expected to be 0.08, and line
efficiency (proportion uptime) in the manual portions of the line = 100%. Repositioning time = 0.15 minute;
however, this time is included in the total labor hours for this (and other) departments, so it need not be
considered in the case problem
 P a g e | 13

The Paint Shop

In the paint shop, a series of processing steps are performed to prepare and coat the car body surfaces.
These steps are: (1) phosphate, (2) prime, (3) base coat, and (4) clear coat. The phosphate process chemically
cleans the surface and prepares it to accept the paint coat. The priming operation adds the first coat of paint.
Base coating is the coat that provides the color to the automobile car body. The clear coat is applied to
enhance luster and complete the coating process. The paint shop is organized into four sections,
corresponding to these steps. Between the sections, there are drying and cooling areas. Figure 3 presents
the organization of work in the department.

Figure 3 - Work flow in the paint shop.

Phosphate Prime Drying Colling Basecoat Drying Clearcoat Drying Wiping
➔ ➔ ➔ ➔ ➔ ➔ ➔ ➔ ➔

Dip tank Dip tank 15 min. 10 min. Manual 10 min. Manual 15 min. Manual+
10 man crew 10 man crew and robotic and robotic Repair loop
The phosphate operation is a fully automated dipping process in which the work carriers, with car
bodies on board, are submerged in a large tank of chemical solution to prepare the body for painting. The
dipping tank is 150 ft long and 15 ft wide. The car bodies are moved through the tanks by continuously
moving conveyor. Immediately following phosphate is prime, with 100 ft of conveyor length (by 15 ft wide)
separating the two sections. The prime operation also involves submersion of the body, but it uses an
electrostatic process to increase the surface coverage of the coating. The prime tank is the same size as the
phosphate tank and is also fully automated. Although automated, phosphate and prime each require a crew
of 10 people for maintenance and monitoring. These crews are included in the direct labor hours per car
allocated to the paint shop.
Following prime is an enclosed drying oven which must permit a total of 15 minutes drying time for
each car body as it moves through. The drying oven is 15 ft wide. Another 10 minutes must be allowed for
the bodies to cool before going into the base coat line. A width of 15 ft must be allowed for this transport
system. The base coat line is a ventilated paint line consisting of a combination of robots and humans to
 P a g e | 14

perform the color base coat. Ten minutes are then provided for drying of the base coat before going into
the clear coat line. Again, the required design width = 15 ft.
The clear coat line is the same space allocation as base coat. After clear coat, 15 minutes are allowed
for drying. The paint drying areas in the plant are 15 ft wide. This is followed by a series of workstations in
which the bodies are manually wiped, buffed, and inspected for painting flaws.
Defects are common in the paint shop. Those cars needing repair enter a repair area and are then
merged back into the line before exiting the paint shop. This repair area = 10,000 sq ft. Painted cars with
defects are simply taken off the regular line, repaired, and then placed back onto the line at vacancies where
other vehicles have been removed for repair. These disruptions in the sequence create only minor problems
in trim-chassis-final so long as the paint quality level remains high on average. The balance delay and other
line factors in the paint shop include the effect of the expected workload in the repair loop.
Not counting phosphate and prime, the average balance delay is 0.10 and the average manning level
= 1.5 on the paint shop workstations. Repositioning time = 0.20 minute. The balance delay and manning
level include the effect of the robotic stations. The paint department should be planned for a line efficiency
(proportion uptime) of 95%. Each station in this department is 25 ft long and 40 ft wide. The extra width is
required for ventilation equipment and associated enclosures.

GENERAL ASSEMBLY SHOP

After painting the General assembly shop complete the vehicle. Hear all the inter exterior parts like dashboard,
engine, lamps, waring, petrol, tyres, windshield, etc. are fitted in the vehicle. And final checkup and inspection and all
are done hear.

Trim-Chassis-Final
seats, dashboard, windows, and other trim are added. Radios and options such as air conditioning are
also added here. Near the end of trim-chassis-final, the engine, transmission, and tires are mounted into the
car.
This is the department in which the automobile is completed. Painted car bodies enter the
department, and finished cars drive off the end of the line. Motors, wheels, transmissions, steering
mechanisms, seats, dashboard, panels, and all of the other trim subassemblies and components are added
in this section of the plant. The parts are delivered to the proper locations by overhead conveyors, forklifts,
and other mechanized methods.
The department has no automation. The balance delay in this department = 0.15, repositioning time
= 0.20 minute, and the average manning level = 3.5. This department should be planned for a line efficiency
of 95%. The average station in this department is 25 ft in length and 50 ft in width (22 ft on either side of
the conveyor)

Reprocess Department
The reprocess area is used to repair cars that suffer some quality defect or need additional work. Cars
coming off the trim-chassis-final line that do not need reprocess are driven directly out of the plant to a
large parking lot, from which they will be shipped by rail or truck to various distribution points.Cars needing
rework are driven or pushed to the reprocess area which occupies a total of 40,000 sq ft. The department
will consist of a sufficient number of individual stalls to service the defective product. Although the
reprocess.
 P a g e | 15

POWERTRAIN SHOP

This shop is different rest all shop it has its own assembly line, machine shop, parts line and all. Hear
the engine production is done. Quality checkup, engine hot test cold test all quality test and engine capacity
is measured hear.

About Powertrain Department

Powertrain Department is divided into two parts

• Machine shop.
• Engine Assembly Shop.

Machine Shop
It consists of “Engine Block “and “Engine Head" Production. Were different types of electric machines
being available for block machining process. Which consists of block boring, excessive material removing,
water jacket work, oil gallery work, and is finished with fine surfaces and accurate design, measurement,
size, testing of block material quality.
In this shop many hydraulic machines like CNC, Grinding, Surface Finishing, Cylinder Holes Boring, etc.
Machine are available hear. Which has a capacity of holding 30 blocks in spare. This machine has around 500
block per day capacity of working.
After this all work this block, head, connecting Rods, Piston, Crankshaft, Camshaft. All parts are
transferred to main Assembly line.

Engine Assembly Shop

It consists of where's lines such as

• Engine Assembly line

• Parts Assembly line
• cold test line
• Hot test line
• Quality inspection line.
 P a g e | 16

Engine Assembly Line

It consists of around 59 stations. Station 1 starts with engine block and after that the conveyor move
according to the cycle time from one station to next station and operator has to finished his work
accordingly. Station 1 were operating attached engine block with the pedestrian and lock it with help of air
runner having a socket of 19mm. And the conveyor moves with cycle time of 12asec and the operator finish
his work. Then the engine block moves at station 2 were operate place the Crankshaft and then some parts
which is give too him. And the engine moves at the same speed of 129sec at ever station. Then it moves at
engine timing station and after timing chains are fitted and robotic machines apply and RTV called client too
front cover of engine. And the operator fittest that part on engine. And engine moves so on too the last
station. Tell the end of station 59 engine is completely assembled and is ready for further testing.

Leak and Cold Test

After the complete of assembly line the engine is removed from the assembly line and is placed in leak
and cold test machine. It takes around 150sec to test one engine. In this fist leak test is done in which engine
is checked ware there is any leakage in gasket or any other gaps of engine fittings. After that oil is filled in
engine and is ready for hot test.
 P a g e | 17

Hot Test.

After the complete of cold test, the engine is removed with help of forklift and placed in rack of hot
test ware engine is runed and tested till end of its capacity and is checked if any abnormal sound, leakage,
or it is getting hot before standard terms, and this process takes around 30min to test one engine. In which
first engine is runed for standard speed and then after some time the engine speed is increased according
to standard terms. After all results are okay in this this process then it is finally ready for quality checks.
 P a g e | 18

Final inspection (Quality checkup’s)

In final inspection engine is over all checked if any process is skipped or any pending work is remaining,
hear they also check that while lifting or testing if there is any damaged on any part. And after all points are
ok it is finally send to general assembly shop to be fitted on vehicle.
The production of components for the automotive industry, high quality standards are required to
achieve longevity and reliability of vehicles. In order to fulfill the high demands, non-destructive visual testing
often takes place during the production process.
In order to achieve the longest possible engine lifetime with efficient function, strict quality
requirements are met during production. For example, the cylinder head and cylinder block are visually
inspected. The focus is on oil bore holes, oil lines and cooling channels. Any casting, sand or chip residue
leads to oil contamination during subsequent operation and accelerates engine wear. During inspection,
each oil bore hole and oil line is tested. Depending on the position of a potential defect or material residue,
the inspector changes the direction of view by replacing the probe. Quickly interchangeable probes and a
handy device ensure efficient operation.
During the final inspection of the cylinder head and cylinder block, the cooling channels are also visually
inspected on a random basis.
The infographics give you an overview of the endoscopic inspection in the engine block and the typical
probes.
 P a g e | 19

Types of engine made by GENRAL MOTOR’S

Until the mid-1970s, most General Motors brands designed and manufactured their own engines with
few interchangeable parts between brands.[1] In the mid-1960s, there were 8 separate families of GM V8
engines on sale in the USA.[2]
By the 1970s, GM began to see problems with their approach. For instance, four different North
American divisions (Chevrolet, Pontiac, Oldsmobile and Buick) offered four completely different versions of
a 350 cu in V8 engine - very few parts would interchange between the four designs despite their visual
similarities, resulting in confusion for owners who naturally assumed that replacement parts would be usable
across brands. In addition to these issues and the obvious overlap in production costs, the cost of certifying
so many different engines for tightening worldwide emissions regulations threatened to become very costly.
Thus, by the early 1980s, GM had consolidated its powertrain engineering efforts into a few distinct
lines. Generally, North American and European engineering units remained separate, with Australia's Holden
and other global divisions borrowing designs from one or the other as needed. GM also worked out sharing
agreements with other manufacturers such as Isuzu and Nissan to fill certain gaps in engineering. Similarly,
the company also purchased other automotive firms (including Saab and Daewoo), eventually folding their
engine designs into the corporate portfolio as well. GM later reorganized its Powertrain Division into GM
Global Propulsion Systems, located in Pontiac, Michigan.[3]
GM's German subsidiary, Opel, relies on a range of three-, four- and six-
cylinder gasoline and diesel engines. A survey[citation needed] of their range shows a reliance on petrol and diesel
four-cylinders, and in 2014, there was only one 3-cylinder engine and one 6 cylinder engine in service in
Opel's passenger car range.
 P a g e | 20

Automotive gasoline engines

Two-cylinder

• 1904-1911 Buick OHV flat-twin[4] World's first production overhead valve engine.
• 1909 Oakland vertical engine[5][6]
Three-cylinder

Daewoo M-TEC inline-three enginee

Inline-3

• 1991–present Daewoo M-TEC/S-TEC (acquired with purchase of Daewoo)

• 1984–present Suzuki G (designed and built by Suzuki)
• 1996–present GM Family 0
• 2013–present Small Gasoline Engine
• 2018-present GM E-Turbo engine

GM Family 1 inline-four engine

 P a g e | 21

Four-cylinder

Cadillac inline-four engine

Saab H inline-four engine

Five-cylinder

GM Atlas inline-five engine

• 2003–2012 Atlas "Vortec" inline-5

 P a g e | 22

Six-cylinder

Chevrolet Stovebolt inline-six engine

Inline-6

• 1908-1912 Oldsmobile Limited (acquired as part of the founding of GM)

• 1913-1923 Oakland Series 60
• 1913-1915 Oldsmobile Series 50
• 1914-1916 Buick Series 50
• 1916-1923 Buick Series 40 (non-removable head)
• 1916-1927 Oldsmobile Series 30 inline-6
• 1923-1930 Buick Removable-Head
• 1923-1928 Oakland inline-6
• 1926-1927 Pontiac Split-Head (also modified for GMC trucks)
• 1928–1936 Chevrolet Stovebolt
• 1928-1950 Oldsmobile F-Series (also used in Buick Marquette)
• 1928–1954 Pontiac GMR (also modified for GMC trucks)
• 1930-1966 Opel inline-6 (as used in the Opel Kapitän)
• 1936–1962 Chevrolet Blue Flame inline-6 (also used in some GMC trucks)
• 1939–1962 GMC inline-6
• 1948-1962 Holden Grey
• 1962–2001 Chevrolet Generation 3
• 1963–1969 Pontiac Tempest (derived from the Chevrolet Generation 3)
• 1963-1980 Holden Red
• 1966-1993 Opel CIH
• 1980-1984 Holden Blue
• 1984-1986 Holden Black
• 1986-1988 Nissan RB30 (used in the Holden Commodore (VL))
• 1999-2011 Daewoo XK inline-6 (marketed as "E-TEC", used in Daewoo Magnus, via
GM's purchase of Daewoo Motor)
• 2001–2009 Atlas "Vortec"
 P a g e | 23

V6

• 1960-1978 GMC V6
• 1960-2008 Buick V6 (marketed as "Fireball V6", "3800", "Dauntless V6" in 1966-1971
Jeeps, and "Ecotec")
• 1977–2013 General Motors 90° V6 engine (derived from the Chevrolet Small-Block"
V8; now marketed as GM Vortec V6)
• 1979–2010 GM 60-Degree V6
• 1994-2005 GM 54-Degree L-81 V6 (used in the Saturn Vue, Cadillac Catera and Saturn
L series)
• 1995–present Suzuki H (used in several models built for GM by Suzuki)
• 2004–2008 Honda J (used in the Saturn Vue)
• 1998-2002 Northstar LX5
• 2003–2011 GM High Value
• 2004–present GM High Feature
• 2014–present GM Generation V "Ecotec3"

Eight-cylinder
From the 1950s through the 1970s, each GM division had its own V8 engine family. Today, there are
only two families of V8 engines in production for road vehicles: the Generation IV small-block and
its Generation V small-block derivative.

Oldsmobile Rocket V8 engine

GM LS V8 engine
 P a g e | 24

Inline-8

• 1931-1936 Buick Straight-8

• 1932-1948 Oldsmobile Straight-8

• 1932-1954 Pontiac Silver Streak

• 1934-1936 LaSalle
• 1936-1953 Buick Fireball

Pontiac Silver Streak eight engine

V8

• 1914-1935 Cadillac Type 51 (also used in the LaSalle)

• 1915-1917 Oakland Model 50
• 1915-1923 Oldsmobile Model 40
• 1917-1918 Chevrolet Series D (acquired as part of Chevrolet's merger into GM)
• 1929-1931 Viking V8
• 1930-1932 Oakland V8 (used in Pontiac models during its final year)

• 1935-1948 Cadillac Series 60 (also used in the LaSalle)

• 1948-1980 Cadillac OHV V8
• 1948-1990 Oldsmobile Rocket
• 1952-1980 Buick Fireball
• 1954-2003 Chevrolet Small-Block V8 "Generation I" (originally "Turbo-Fire")
• 1954-1980 Pontiac V8 (also modified for GMC Truck models)
• 1958-1965 Chevrolet W (also referred to as "Turbo-Thrust")
• 1961-1963 GM Aluminum V8 (now better known as the Rover V8 and also
the Repco V8 Formula One engine)
• 1965-2009 Chevrolet Big-Block V8 (originally "Turbo-Jet")
• 1966-1970s GMC Truck V8 (derived from the GMC V6)
• 1967-1984 Cadillac New V8
• 1969-1984 Holden 253
• 1969-2000 Holden 308 (stroke reduced in 1985, making it 304 cu in (5.0 l); 350 cu in
(5.7 l) version also produced from mid 1994 for use by HSV)
• 1981-1995 Cadillac HT
• 1990-1995 Chevrolet LT5 (exclusive to the Chevrolet Corvette ZR1)
• 1991–2010 Northstar V8 (also used in the Oldsmobile Aurora)
 P a g e | 25

Automotive diesel engines

Three-cylinder

• 2020–present
Four-cylinder

• 1970-1977 Opel 2.1 litre

• 1975-1981 Opel 2.0 litre
• 1982-1988 Opel Family II 1.6 liter (16DA/16D)
• 1982-1993 Opel 2.3 liter (23YD/23YDT/23DTR)[17]
• 1982-2000 Isuzu E (1.5 and 1.7 liter engines marketed as D or TD for Opel/Isuzu cars)
• 1990–2014 Isuzu Circle L (marketed as Ecotec DTI, DI or CDTI; acquired via GM's
• 2003–present Fiat 1.3 JTD (marketed as Ecotec CDTI or Ecotec depending on brand)
• 2003-2010 VM Motori RA 420 (marketed as Ecotec 2.0 CDTI or 2.0 VCDi depending on
• 2004–2009 Fiat 1.9 JTD (marketed as Ecotec 1.9 CDTI or 1.9 TiD/TTiD depending on
• 2008–present GM Family B "2.0 CDTI"
• 2011–present Family Z (marketed as "2.0", "2.2 VCDi" or "2.2 CDTI")
• 2012–present 2.5 and 2.8 litre Duramax[18]
• 2013–present GM Medium Diesel "1.6 CDTI Ecotec"[19]
• 2014–present GM Large Diesel "2.0 CDTI Ecotec"[20]
Six-cylinder

• 1980s-present Detroit Diesel 60 inline-6

• 1982-1985 Oldsmobile V6 Diesel 4.3L (the lesser-known counterpart to the infamous
• 1994-2003 BMW M51 2.5 liter (X25DT/U25DT/Y25DT)
• 2002–present DMAX V6 (acquired via GM's takeover of DMAX)
• 2019–present Duramax I6
Eight-cylinder

• 1977-1985 Oldsmobile Diesel engine

• 1982-2000 Detroit Diesel V8 6.2L and 6.5L (6.5L engines are still in production by AM
• 2001–present Duramax V8 (acquired via GM's 2003 takeover of DMAX)
 P a g e | 26

Other diesel engines

• Detroit Diesel Series 92 engines

• GM entered the diesel field with its acquisition of the Cleveland-based Winton Engine
Company in 1930. Winton's main client was the Electro Motive Company, a producer of internal
combustion-electric rail motorcars. GM acquired Electro Motive at roughly the same time as Winton.
• A partnership of GM's Research and Development Division and their Winton Engine
Corporation delivered their first diesel engines suitable for mobile use starting in 1934. The engines
were also sold for marine and stationary applications. In a 1938 reorganization, Winton Engine
Corporation became the GM Cleveland Diesel Engine Division, and GM's Detroit Diesel Engine
Division began production of smaller (50–149 cu in (0.8–2.4 l) per cylinder) diesel engines.
Locomotive engines were moved under the GM Electro Motive Division (EMD) in 1941, while
Cleveland Diesel retained development and production of large marine and stationary engines.
• Cleveland Diesel was dissolved in 1962 and their remaining production moved to EMD. In
1988, the Detroit Diesel Engine Division was incorporated as an independent company, later acquired
by DaimlerChrysler in 2005. EMD was sold off by GM in 2005 and is now a subsidiary of Progress Rail
Services
Locomotive engines

• 1934-1938 Winton 201-A (multi-purpose)

• 1938-1966 EMD 567
• 1965-1988 EMD 645
• 1984–present EMD 710
• 1998–present EMD 265
Marine/stationary diesel engines

• 1934-1938 Winton 201-A (multi-purpose)

• 248 (8, 12, 16 cylinder)
• 258 (12 cylinder, 4 stroke, direct reversing)
• 258S (16 cylinder, 4 stroke, turbocharged, direct reversing)
• 268 (3, 4, 6, 8 cylinder)
• 268A (3, 4, 6, 8 cylinder)
 P a g e | 27

• 268A NM (8 cylinder)
• 278 (6, 8, 12, 16 cylinder)
• 278A (6, 8, 12, 16 cylinder)
• 278A NM (8, 12 cylinder)
• 241 (6 cylinder - 4 stroke)
• 288 (12 cylinder, direct reversing)
• 338 (16 cylinder, vertical radial)
• 498 (8, 12, 16 cylinder)
• 498 NM (8 cylinder)
• 358H (16 cylinder, horizontal radial)

Heavy and off-road diesel engines

• 1938-1995 Detroit Diesel Series 71

• 1945-1965 Detroit Diesel Series 110
• 1950-1955 Detroit Diesel Series 51
• 1957-1990s Detroit Diesel Series 53
• 1960s-1980s Detroit Diesel Series 149
• 1974–present Detroit Diesel Series 92
Aircraft engines
Piston

• 1931-1944 Allison V-1710

• 1937-1944 Allison V-3420 (derived from the V-1710)
Propfan
• 1987-1989 *Allison 578-DX
Turboprop

• 1947-1950s Allison T38

• 1953-1955 Allison T40
• 1954–present Allison T56 "501-D" (also produced by Rolls-Royce)
Turboshaft

• 1954–present Allison T56 "501-D" (also produced by Rolls-Royce)

• 1960s-present Allison 250 (also produced by Rolls-Royce)
Turbojet

• 1944-1959 Allison J33 (originally developed by General Electric and transferred to GM for
production)
• 1946-1955 Allison J35 (originally developed by General Electric and transferred to GM for
production)
• 1948-1958 Allison J71
 P a g e | 28

GM Medium Diesel engine

The Medium Diesel Engine (MDE) is a four-cylinder diesel engine developed by Adam Opel AG and
branded "1.6 CDTI Ecotec" in most markets. Opel also adds the marketing term "Whisper Diesel" in some
markets, claiming relatively low levels of noise, vibration, and harshness. Production commenced in late
2013 at Szentgotthárd, Hungary. The MDE is Opel's first all-aluminum diesel engine and offers a power
density of 85 hp (63 kW) per liter 136 PS (100 kW; 134 hp) in its most powerful version. Maximum power
and torque have been increased versus the previous-generation 1.7-liter engine, while fuel consumption has
been reduced by up to 10 percent compared with a 2.0-liter CDTI engine of similar power output.[1] This new
1.6 CDTI engine will replace the current 1.7-liter and lower-powered 2.0-liter diesel engines in a wide range
of Opel models, with more- and less-powerful versions to come. The most powerful version of this engine,
delivering 136 PS (100 kW; 134 hp) at 3,500–4,000 rpm and 320 N⋅m (236 lb⋅ft) at 2,000 rpm, was first
introduced in the 2013 Opel Zafira Tourer,[2] and later in the 2014 Opel Astra J and restyled 2014 Opel Meriva
B. In 2014, versions were released with power outputs of 110 and 95 PS (81 and 70 kW; 108 and 94 hp).
The engine's displacement is 1.6 L (1,598 cc) and it has a bore/stroke ratio of 79.7 mm × 80.1 mm
(3.14 in × 3.15 in), attaining cylinder pressures of 180 bar (2,600 psi) and a compression ratio of 16.0:1. It
uses an aluminum engine block, die-cast aluminum bedplate, and an aluminum cylinder head. A chain
driven dual overhead camshaft, employing weight-saving hollow sections and lobes, operates four valves
per cylinder with low-friction, hydraulic roller finger followers. The pistons are made from aluminum for
reduced reciprocating mass, feature a concave, shallow-bowl profile to facilitate efficient combustion, and
are cooled by under-skirt oil spraying. The crankshaft employs four counterweights to minimize mass, and
both it and the con-rods are made of forged steel. The engine features multiple improvements to
reduce NVH, such as a cam cover made of GRP and fully decoupled from the engine to reduce noise and
vibration, while also saving weight compared to aluminum; a composite intake manifold encapsulated in
acoustic padding as well as an external plastic shield that both significantly reduce noise emissions; a
mechanical crankshaft isolator which reduces radiated noise and torsional vibrations in the accessory drive
system; and scissor gears for the timing drive system, incorporating tooth profiles ground with a Low Noise
Shifting (LNS) process for optimal noise reduction. More than 150 patented diesel control functions are
deployed by the engine's ECU, which was developed in-house by General Motors and jointly engineered in
Italy (by GM Powertrain Torino), Germany, and the United States, and will be used in all future GM four-
cylinder diesel engines.
Low fuel consumption and Euro 6-standard emissions (effective from September 2015) are also made
possible by the use of Opel’s “BlueInjection” selective catalytic reduction (SCR) system, which injects AdBlue,
a urea-and-water solution, into the exhaust stream. The solution decomposes into ammonia, which is then
stored on a catalyst substrate. When nitrogen oxide (NO
x) from the exhaust gases enters the catalyst, it is then selectively reduced to nitrogen and water.
From 2013, this engine replaced the 1.7 L CDTI as well as lower-powered variants of the 2.0 L
CDTI Ecotec 110 and 130 PS (81 and 96 kW; 108 and 128 hp) engines in Opel cars, and also superseded
the 1.3 L CDTI engines in the Corsa, Meriva and Astra. GM also introduced the MDE engine in the 2017
Chevrolet Cruze and 2018 Chevrolet Equinox sold in the United States.
 P a g e | 29

A bi-turbo version with 160 hp (119 kW; 162 PS)/356 N⋅m (263 lb⋅ft) is used in:

• 2016 Opel Astra K [3]

The 136 PS (100 kW; 134 hp)/320 N⋅m (236 lb⋅ft) version (code B16DTH) is used in the following vehicles:

• 2013 Opel Zafira Tourer C

• 2014 Opel Astra J
• 2014 Opel Meriva B
• 2015 Opel Mokka
• 2015 Opel Insignia A
• 2017 Opel Insignia B
• 2015-2018 Chevrolet Orlando sold in South Korea
• 2015 Chevrolet Trax sold in South Korea
• 2015 Opel Astra K
• 2016-2019 Chevrolet Cruze
• 2018-2019 Chevrolet Equinox
• 2018-2019 GMC Terrain
The 120 PS (88 kW; 118 hp)/320 N⋅m (236 lb⋅ft) version is used in:

• 2014 Opel Zafira Tourer C

• 2015 Opel Insignia A
• 2017 Opel Insignia B
The 110 PS (81 kW; 108 hp)/300 N⋅m (221 lb⋅ft) version is used in:

• 2014 Opel Astra J

• 2014 Opel Meriva B
• 2015 Opel Mokka
• 2015 Opel Astra K
The 95 PS (70 kW; 94 hp)/280 N⋅m (207 lb⋅ft) version is used in:

• 2014 Opel Meriva B

• 2015 Opel Astra K
 P a g e | 30

Machine and Equipment Used

CENTROID CNC Engine Block Machining Center. Super wide machine base yields ultra-accurate
cylinder block CNC boring and surfacing. Heavy duty rotary axis and advanced rigid block featuring provides
the industry's best CNC block machine. Machine Blocks and Parts with the same machine. Conversational
Block Specfic Programming

Automatic CNC Block Blueprinting: CNC Probing

Blueprinting any block begins by making very accurate measurements

of the existing features so corrections can be made. The old way of laborious manual measurement has been
eliminated. The CENTROID CNC Block machine is equipped with a high tech digitizing probe which
automatically locates and measure cylinder bores (diameters, locations and angles), deck heights, and lifter
bores with our exclusive easy to use block specific conversational software. To measure an entire block,
simply choose the features to blueprint and the probe automatically measures the block and displays the
actual diameters and positions of the cylinder bores (and other features) and compares it to the factory
specs. The operator then chooses to make any modifications necessary.
 P a g e | 31

CNC Engine Block surfacing.

With a quick push button tool change the machine will surface the block to the exact deck height
specified. The probe automatically detects the block existing surface height at multiple locations so the
operator can choose the proper surface depth to machine to for a perfectly flat and square deck to the
cylinder bore. Specialized CNC block surfacing tooling is included which produces incredibly smooth surfaces
for superior gasket performance.

CNC Engine Block Boring

Automatic Boring cycles are pre programmed and are menu driven with a simple fill-in-the-blank
format. 360 degree CNC rotary axis will position the block at the exact blueprint angle automatically.
Machine both cylinder banks with the same setup. Block data base saves your work for future jobs. Bore on
probed centers, Blueprint or any other specified location. Specialized boring tooling included. Quick, simple
programming gets the job done accurately the first time. Operators program the block work to be done right
at the machine
 P a g e | 32

Head Stud conversion, automatic, drill, counter bore and tap... just takes minutes.

Convert blocks for head studs with ease. The machine will automatically drill out the exisiting threads
counter bore the lead in and rigid tap (or threadmill) the threads to accept the new head studs. The
CENTROID user friendly CNC Block software is conversational format which means all you have to do is fill in
the blanks with the basic block information, no need to go out of house or learn G-codes, our easy to learn
Block Software is made specifically for engine builders saving you time. You can save all of your programs
and base new ones off of existing work, building a custom group of block machining programs.

CNC Lifter Bore Machining

Machine lifter bores to the exact diameter, location and angle needed with one simple setup. True up
the stock size and location or bore complete new diameter, location or angle. Easily control feed and speed
within the CENTROID conversational software, the computer remembers your data for the next job as well,
no need to reprogram. Easy manual override of programmed feeds and speeds via the operator control panel
makes fine tuning adjustments easy to do on the fly
 P a g e | 33

CNC Spot Facing

Spot Face Lifter bores automatically. You have the ability to create and save your programs with
CENTROID user friendly CNC Block software. No need to go out of house or learn G codes, our easy to learn
Block Software is made specifically for engine builders saving you time.

4 bolt Main Bearing Cap Conversion

The best way to accurately convert a block to 4 bolt mains. Automatic CNC drill and tap routines are
pre programmed, the operator simply answers a few questions and the machine does the rest. CNC Angle
Drilling and tapping for perfect 4 bolt main conversions.

O-ring Grooving

Add O-ring grooves the the deck of any block. Any width and any depth, operator specifies oring specs
and the machine does the rest
 P a g e | 34

Cylinder Chamfering

Chamfer cylinders automatically. Operators specifies amount of chamfer. Machine chamfers perfectly
concentric with bore.

CNC Block Lightening

Automatically remove excess material. The probe copies the shape of the block and creates a
toolpath tha tperfectly matches the contour of every detail.
Choose the amount of material to remove and press cycle start and the tool will machine the block surface
to your specs.

Threadmilling freeze plug holes. (and other threads)

CENTROID threadmilling canned cycle provides easy fill in the blank programming. Threadmill the
threads on blocks and heads. Never break a tap again!When should a thread mill be selected over taps?In
general, for production threading up to 3/8", taps are more efficient. However, if producing a wide variety
of parts, threads, and materials on the same machine, threads mill are far more versatile. They will produce
right or left hand, internal or external threads, single or multiple lead from #2-56 with the same mill.
Materials range from soft, non-ferrous alloys to heat-treated steels, or tough alloys such inconel and
titanium, where tap breakage often occurs. Pipe threads are easily produced without leaving the normal
“stop lines”.
 P a g e | 35

Cylinder Head surfacing! Acheive incredible Ra's

Switch from Block work to Cylinder head surfacing in minutes, surface heads better and faster than a
dedicated surfacing machine. Super Low Ra's will make your customers happy.

Stroker crank clearance machining.

Easily machine clearance paths in the block for big stroker

cranks

CNC Engine Block Engraving

Quickly and easily engrave letters, numbers, symbols and logos. Phone numbers, serial numbers, web
addresses and company logos are now simple to automatically add onto every block you blueprint.
 P a g e | 36

Office Space
On the plant floor, an allowance of 3,000 sq ft must be provided in each of the three major
departments for office space for supervisory, clerical, maintenance, and other factory support staff. No
office space is provided in the reprocess department.
The plant must also have a front office for the management, technical, secretarial, and related staff. A
total of 100,000 sq ft must be allowed for this office, to be located at the front of the plant. This space
includes a cafeteria which is used by assembly workers and office staff.

Aisle, Dock, and Storage Space

An allowance of 35 percent must be added to the floor areas of each of the three departments for
aisle space and rest room facilities. These allowances should be added to the total assembly space, not
including office space.

In addition, receiving docks must be provided with limited space for temporary storage. A total of
30,000 sq ft must be provided for this purpose near the front of the body shop, for storing and preparing of
the body panels prior to launching onto the body shop line. This space is not considered part of the body
shop. Another 25,000 sq ft should be provided following trim-chassis-final and reprocess. This space serves
as temporary storage for finished product and as overflow space for the reprocess department.

Conclusions
Different departments in industry. How work is done in Assembly line. Which type of tools are used
in Assembly line, how engine machining is done engine boring, head facing, valve lapping, etc. Hydraulic
tool, runners, different sockets, etc. Engine Assembly line work, cold test, hot test, quality checks.
Standard of making engine climate of engine room, etc. Standardized work systems, time to time work
with quality products. Keeping work place clean.
Warning’s safety equipment like hand gloves, goggles, helmets, safety shoes, no warning rings,
watches, or chain in neck. Safe distance from automatic machine. Always to do what you see first. All this
I have learned from this training.

Here are some ‘videos links' of how industry work.

1.https://youtu.be/rEElWncU3oU
2.https://youtu.be/c-kd8Bu7UXY
3.https://youtu.be/dtCaPvE6IVw
4.https://youtu.be/IglK_QAsCeI
5.https://youtu.be/5sIeSRPGSdQ
BUTLA PRANAV SHRINIVAS.

(Name of Student)

E.N..Number 192186.