Weld shop
The production process in the weld shop starts by manufacturing of subgroups – smaller car body units, such as doors, parts of the floor or the roof. The ratio of automation in production of subgroups is approximately 50%. Completion of large units and the final car body are provided by fully automated line working within one tenth of a millimeter precision.
At first, the robots weld the front and rear parts of the floor into one. The completed floor then moves to a totally revolutionary type of a production line – the so-called global body line, where other parts are welded to the chassis – sides, dashboard and roof. The weld shop contains over 200 robots of various types. 2220 welds are made on the car during the welding process, using spot and arc welding in protective atmosphere. When including welds made at suppliers on smaller parts, one car has a total of 3 300 welds.
When the car body is completed and adjusted, it passes to the main welding line, where robots perform strong welds, strengthening the whole car body. This step is followed by installation of minor body parts and installation of doors and the hood. The car body is then taken to individual quality inspection and then to the paint shop.
