How are cars made? [ Infographic ]

Are you wondering “How are cars made?”. If so, you’re certainly not alone. Cars are such powerful, complex machines that it’s no surprise that people are interested in how they’re constructed. In this article, we’ll delve deep into this topic, helping you find out more about the car manufacturing process. 

The car manufacturing process

Whilst the car manufacturing process has seen some changes, some things have stayed the same. Even today, the building of cars still takes place on a production line. They move from one station to another during each step of the manufacturing process. One change is that there are now more robots playing a part in the process. These robots can carry out as much as 95% of the work in some cases. They can even lift components up to a weight of 100kg. 

Humans are still essential during the process though, especially for checking work, operating machines, and carrying out challenging tasks such as fitting small components and ensuring items are properly in place.

Has car manufacturing changed in any other ways?

The Toyota Production System or TPS has been a huge influence on the car production process over the years. A great deal of this philosophy focuses on keeping waste to a minimum. This process now takes place in countries around the world. A key principle of the philosophy is to ensure production comes to a halt after the identification of any fault.

Does the production of all cars involve automation?

In some factories, jobs that could be carried out by robots are still done by hand. These can include painting and applying sealant. In some factories that produce luxury vehicles, humans carry out the vast majority of the work. Some high-end cars are made completely by hand and are tailored to the specific requirements of the buyer. Keep reading to learn how are cars made.

Making car components

The manufacturing of car components normally happens away from the factory assembly line. Stringent testing takes place before they arrive on the assembly line to be put together. One of the first parts of the car manufacturing process is to gather the components together. The production of most car parts takes place away from the site. Sometimes the same company makes them, but third parties can produce them too. There are thousands of component producers in the industry.

Making car bodies

Manufacturers use rolls of steel to make car bodies. These need moulding into shape via large dies before welding together the parts can take place. Today, the car structure, chassis, body and frame are all the same unit.

Painting cars

Once the body has been carefully checked over and cleaned, it is ready for painting. Special oils are applied to cars under bright white lights so defects can be identified and repaired before the application of paint takes place. The painting process can begin once the car has ‘pristine’ status. 

Anti-corrosion measures need to take place before the painting process begins. It’s then necessary to dip car bodies into various tanks to clean and prepare the metal. 

The car is also dipped into an undercoat inside an electrostatically charged container as part of the e-coating process. The coated shell then needs to be baked at a temperature over 200°C before the panels undergo sealing. The painting process can then get underway. Robots spray a minimum of three coats onto the car body. These coats include a primer to ensure a smooth surface, a basecoat that has the main colour and a topcoat that works as a protective barrier.

Installing the car engine

The production of the engine is normally off-site. Human workers control robot arms to install the engine and transmission into the vehicle. Human workers install the radiator and bolt it into place.

Installing fixtures and fittings

Robots do most of the work when it comes to adding further parts to the shell. These include the drive shafts, braking systems, steering components, steering wheel, rear axles, gearbox and gas tank. Humans carry out the fitting and bolting work.

Assembling the interior

Humans carry out most of the internal fitting work. This includes installing the dashboard, interior lights, wiring systems, pedals, carpets and media systems. Robots then install the windscreen, which needs a sealant coating on its edges before it goes into the body of the car. Once a water resistance test is complete, work on the final trim can begin. This involves the installation of the battery, tyres, petrol and antifreeze. Tests and audits take place after each factory phase. The car gets a Vehicle Identification Number when it joins the production line. This ensures it’s easy to keep track of the progress of each vehicle.

Who can help with MOTs in Barnsley?

Now you know more about how are cars made, you may be wondering who can help when you need an MOT test centre in Barnsley. At Wyatt, we have been carrying out MOTs in the town for many years and can offer some of the best prices on the local market. We can carry out repair work whilst you’re on site and always aim to get you back on the road as soon as we can. We are proud to have Department for Transport approval and are able to carry out MOTs on all makes and models. What’s more is that we are also a member of the Good Garage Scheme.

Get in touch

Many people choose our MOT test centre in Barnsley when they’re looking for a reputable car maintenance specialist with years of experience to draw upon. To book your vehicle for an MOT, contact us today. You can reach us by giving us a call on 01226 979 087 or by completing the form on our site. We will get back to you as quickly as we possibly can.