HYUNDAI PLANT EXPERIENCE
MY MOTIVATION
When I was working at Smirnov Design I realized that industrial design had much deeper roots that I had thought before. I got extremely interested in technical side of project development. Suddenly I understood that I wanted to look at it from the inside. Luckily my qualifications in plastic part design and CAD knowledge were enough to got hired as an engineer by a huge automotive plant - Hyundai. My position was - engineer in the exterior parts quality control department.
MY RESPONSIBILITIES
My responsibility at Hyundai Motor Manufacturing was exterior parts quality control. If there were a problem with an exterior part, I had to identify and fix it. Here are a short list of parts in my area of responsibility:
PROBLEM INVESTIGATION PROCESS
My main goal was: to investigate cause of defect, problem or malfunction. I had to develop improvements to eliminate defects.
That was a unique opportunity to take a look at manufacturing from the inside.
REPORT & TEST MAKING
After problem evaluation I had to make a report with all information found. Here I made several chamber tests to recognize the cause of the malfunction.
However nobody could understand the reason even a supplier.
INVESTIGATION
To understood a problem I needed to get complete understanding of working principles of the part.
Solenoid
Bearings & shaft
Spring
Shield & bracket
HOW IT WORKS
There is an explanation image of the bezel below.
Low beam
High beam
DEEPER & DEEPER
I got the specification from the supplier. Very interesting how deep the rabbit hole was.
Plunger Part for operationing the shield
Du-bush 작동시 가이드 역할
Housing 흐름의 통로를 만드는 기능
Coil Generates a magnetic field
Core It has been magnetized by the magnetic
field generated by the electromagnet to move the Coil and Plunger Plunger
Terminal Delivers current to the Coil
Bobbin Secondary winding
Diode Prevent reverse voltage and
counter-electromotive force
Plate
Guide rod
Wire assy
RESULT
After different types of analysis and tests a countermeasure was developed and this problem was successfully solved.
PRODUCTION BEAUTY
Actually the whole plant and production processes made a huge impression on me. I want to share my amazement with you. Here some photos from there:
PRESS SHOP
Side outer panel - is a steel solid pressed part.
This is perhaps the most stunning part at the whole plant.
PRESS MAINTENANCE
It's the same part as above in a maintenance shop.
There are several dies during checking process in the distance.
My responsibility at Hyundai Motor Manufacturing was exterior parts quality control. If there were a problem with an exterior part, I had to identify and fix it. Here are a short list of parts in my area of responsibility:
MY RESPONSIBILITIES
MY RESPONSIBILITIES
SIDE OUTER PANELS
WELDING SHOP
There is a roof welding operation. On upper left there are stamped pieces in stock.
BODY SHOP QUALITY CONTROL
Random body is selected and then fully checked for dimensions every day.
ASSEMBLY SHOP
Conveyor. Many thanks to Henry Ford.
ASSEMBLY
The blue colored part is made for body protection during assembly process.
TECHNICAL BEAUTY
It's unbelievable how many different parts form the entire vehicle. Unbelievable.
YARD
Every 54 seconds new vehicle leaves the conveyor.
There is round the clock production. About 900 vehicles are made per one day. Overall production capacity is 220 000 vehicles per year.
Special thanks to Georgy Tolstoy for such an impressive photage.