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.