Assembly Process

Sr no Assembly Process Min Skill Reqrd Critical/Non-Critical

1 Packaging & Material Handling Non-Critical

2 Punching Operation Non-Critical

3 BOP/Child part Assly Non-Critical

4 Screwing Operation Non-Critical

5 Pasting Operation Non-Critical

6 Welding Operation Critical

 Automotive Technologies & Engineering
Question Paper for Evaluation L1 to L2

Operator Name : Date :

Opearator ID : Obtained Marks :
Department : Total Marks :

Note : Each question having 2 marks

Stage Sr.No. Question A B C D Ans Mark Obtained

Punching Operation Packaging & Material Handling

1 What PPE should be wear before packing of parts Gloves Helmet Goggles All

2 Part should be packed only in poly bags True 0

1 3 Part should be kept only in BIN TROLLEY Standard Boxes All

4 Before making box what should be check Remove previous Remove previous Box should be in ok All
stickers tapes condition

5 How you will move the material from store to assembly By Hand By Truck By pallet By conveyer
line ?

1 What is the air pressure range to be required at punching 2 to 3 Bar 3 to 5 Bar 6 to 8 Bar 4 to 6 Bar
operation?

2 2 Start-up Check sheet should be filled at Shift End 1 0

3 "Punching Missing" defect is…….. Reworkable Non Reworkable

1 Which colours clip is used in door trim ? Orange White Black All above
BOP/Child part Assly

2 How much brass insert assemble in U206 spoiler? 8 16 4 6

3 3 Write any two BOP parts used in front bumper assly?

4 Which child parts used in M&M doort trim?

5 Write down any two reworkable defects name on your

station.
Screwing Operation

If NC found in start up which sign to be indicate in start-

1
up check sheet? × − √ NA

4 2 What PPE should be wear at screwing operation? Gloves Helmet Goggles All

3 How much screwing gun Torque required at bumper &

grill assly station? 1.4±0.4 2 to 3 2.0±0.2 both a & b

1 Which part pasted at safari roof rail assly? Gasket Upper Cover Lower Cover All
Pasting Operation

2 What is the air pressure range required at M&M fabric 2 to 3 Bar 3 to 5 Bar 6 to 8 Bar 4 to 6 Bar
pasting station ?
5
3 Poka yoke availble at fabric pasting operation 1 0

4 Which model door trim having Fabric? Low Mid High both a & b

1 How many type of welding done in assembly ? 2 4 6 8

Welding Operation

2 How much temperature required at welding machine on 65 to 75 C 75 to 95 C 85 to 95 C 85 to 105 C

M&M DRT assembly?

Ultrasonic Heat Stacking

6 3 Which type of welding done at M&M DRT assembly?
Welding Welding
Both a&b All

4 What is the air pressure range required at welding 2 to 3 Bar 3 to 5 Bar 6 to 8 Bar 4 to 6 Bar
operation ?

5 Which type of welding done at VW DRT assembly? Ultrasonic Heat Stacking Both a&b ALL
Welding Welding

EXCELLENT : 90% & above VERY GOOD : 80% & above GOOD : 70% & above PASS : 60% & above TOTAL MARK
 Automotive Technologies & Engineering
Question Paper for Evaluation L2 to L3
Operator Name : Date :

Opearator ID : Obtained Ma:

Department : Total Marks :

Note : Each question having 2 marks

Sr no Stage Sr.No. Question A B C D Ans Mark Obtained

Packaging & Material Handling

1 Before taking box/trolly from WIP area to be check Identification Quantity as per Packaging All
sticker sticker condition

More Searching Extra space

2 If material is not kept on identified location Material mixup All
time occupied
1

3 What is the stacking height for Box 2 Boxs 5 Boxs 3 Boxs 8 Boxs

4 What is the FIFO ?

Punching Operation

1 Write down any two defects name on punching operations

Roatated knob Roatated knob

2 2 For adjusting high air pressure which side to be rotated ?
Anticlock Clockwise
Pull the knob Push the knob

If power is off during the punching operation which document will Defect Decision
3 follow AIS Abnormal situation Matrix both a & c

1 Which Child parts used for VW door trim assly? Insert Armrest Map Pocket All
BOP/Child part Assly

2 Write any three BOP parts used safari roof rail assly?

3 3 Which parts required for Case1 front bumper grill assly? Painted grill bottom bezel Top bezel All

4 Which BOP used for door trim assly? Screw Foam Clip All

5 Which colours handle used for VW door trim? Walnut Tabora black All

Adjuster rotating Adjuster rotating It is adjust

1 How to adjust screwing gun torque if it is lower than standard ? clockwise anti clockwise automaticaly None of these
direction direction
Screwing Operation

How much screwing gun Torque required at handle assembly

2 station? 1.4±0.4 2 to 3 2.0±0.2 both a & b

4
3 Screwing gun torque can be adjustable 1 0

4 Which direction switch of screwing gun shifted for loosing screw ? Upward Downward Middle Forward

Write down three colours types of fabrics which are used in door
1 trim
Pasting Operation

2 Write down any two defects name at pasting operation

5
Primer pasting Map pocket &
3 Which Poka yoke is used at Fabric pasting station? bottle holder Bush missing None of above
missing missing

4 "Excess fabric" defect is…….. Reworkable Non Reworkable

Map pocket &

1 Which Poka yoke is used at M&M DRT welding station? Jack nut missing bottle holder Bush missing Non of above
missing

2 Which Defect will occur during Welding? Weak Weld Miss punch Weather strip gap Excess fabric
Welding Operation

6 3 What will happen, if air pressure is low on ultrasonic welding SPM? Weak Weld Deep Weld No effect both a & b

Map pocket &

4 Which Poka yoke is used at VW DRT welding station? Jack nut missing bottle holder Bush missing Non of above
missing

5 What will happen, if air pressure is High on Heat staking machine? Weak Weld Deep Weld No effect both a & b

EXCELLENT : 90% & above VERY GOOD : 80% & above GOOD : 70% & above PASS : 60% & above TOTAL MARK
 Automotive Technologies & Engineering
Question Paper for Evaluation L3 to L4

Operator Name : Date :

Opearator ID : Obtained Ma:

Department : Total Marks :

Note : Each question having 2 marks

Stage Sr.No. Question A B C D Ans Mark Obtained

If without QA sticker part received for Inform to QA Part put in to FG Part put as it is on Part put into
1
Packaging & Material Handling

packaging, what will you do ? person trolley stand rejection trolley

2 What is the pakaging capacity defined for 7 28 21 14

U206 bumper trolley ?

1 Start the Do not start the Pack the material

3 If standard packaging material is not production production into non std. Both b & c
available ? without without std. packaging
packaging packaging

If packaging is short for one part, then keep

4 the parts in same box or trolly. True 0

1 If part not properly fix into fixture what will Uneven punching Ok punching Miss Punching All
happen ?
Punching Operation

If machine running in ok condition, then

2 which light will show signal tower? Red Green Orange None of these

2
3 What will effect, if air pressure is high than Punching not None of these
defined? Part get Machine not done
damaged work

4 How Many Abnormal Situation is applicable 6 5 7 9

at punching operation ?

Write down any two possible causes of

1 bumper damage ?

Which procedure u will follow If BOP Abnormal NC part handling Start up procedure Set up procedure
BOP/Child part Assly

2
missing for assembly ? Situation Procedure

List down the BOP used for one U206 with

3 3 fog bumper?

Immediate
Dog house of clip is short mould, then what Assemble clip as feedback raise for Put the part in
4 u will do? it is yellow bin Both a & c
concern

5 Wrong map pocket assembly defect is True 0

reworkable ?

Write any three Abnormal Situation which

Screwing Operation

1 are applicable at Screwing operation ?

How Many Abnormal Situation in Abnormal

4 2 Situation procedure 6 5 7 9

3 What will happen if screwing gun torque is Screw thread Screw thightning No effect on part Deep weld
less than standerd range ? damge loose

What is the adhesive used for roof rail Primer & Pramoter & Pramoter & 3M
1 gasket pasting ? lohmann tape Masking tape tape Both a & c
Pasting Operation

2 BSPM K520 Primer is used for Gasket True 0

pasting ?

5 Follow the
If flash defect found before pasting of Immediate Put the part into Put the part into
3 gasket ? feedback red bin Assemble the part yellow bin
mechanism

4 What is the adhesive used for Fabric pasting Primer SL 1017 BSPM K520 Primer Primer 94 -3M 3M tape
at M&M DRT assembly?

Write down any two possible causes of

1 Weak weld ?

Cantrail Welding Robot is working but not Robot Controller Ultrasonic Air pressure is
Welding Operation

2 Stabiliser is off
weld the points, it means is off controller is off high

Which defect will occure if tool learning not

6 3 done after tool change on vw assembly ? Weak weld Deep weld Wrong assembly Both a & b

Write down the three component name of

4 ultrasonic welding system ?

5 Write down any two possible causes of

Deep weld ?

EXCELLENT : 90% & above VERY GOOD : 80% & above GOOD : 70% & above PASS : 60% & above TOTAL MARK