Honda ACCORD Assembly🚘2024: How it's made?😲Production line video➕Crash Testing & FACTORY TOUR

Summary

The Honda Accord's manufacturing process at the Marysville Auto Plant in Ohio is detailed, showcasing the transformation from steel rolls to finished vehicles. Key stages include cutting, pressing, welding with over 900 robots, painting with a new 2K primer process, and assembly. Innovative techniques like high-performance adhesive and laser brazing enhance quality. The plant's commitment to efficiency and sustainability is evident through energy-saving technologies and water recycling.

Takeaways

• 🏭 The Honda Accord is manufactured at the Honda Marysville Auto Plant in Ohio, which is one of the most integrated and flexible auto plants in North America.
• 🔩 The production process starts with steel that undergoes a blanking process to cut it into specific shapes, followed by a four-stage press process.
• 🔍 Quality control is emphasized with associates inspecting parts for flaws and defects after the press process.
• 🚗 The forming department is responsible for making bumpers, boomerangs, and dashboards, with different machines assigned to specific parts.
• 🤖 The welding department is highly automated with over 900 robots, including handling, ceiling, and welding robots, working across a large area with over 800 associates.
• 🏗️ Innovative areas introduced include the inner frame, roof razor area, and high-performance adhesive, enhancing the car's quality and rigidity.
• 🎨 The paint department applies new colors to the cars after they leave the weld shop, involving a series of processes including cleaning, sealing, priming, and coating.
• 🛠️ The assembly process includes the installation of interior parts, engine mounting, and rear suspension, with a focus on timing and efficiency.
• 🔍 Rigorous quality inspections are conducted, including a 200-check item list, exterior and lock function checks, and a dyno area for alignment and feature tests.
• 💧 A unique feature is the use of a 2K primer, a two-part primer process, and a waterborne coating system in the paint shop to reduce emissions.
• 🌱 Environmental sustainability is a focus, with investments in energy-efficient facilities, water recycling systems, and reduced emissions in the paint process.

Q & A

What is the initial process for creating a Honda Accord?

The initial process involves taking a roll of steel, cutting it into specific shapes through a blanking process, and then pressing it through a four-stage die press which includes a draw die, trim die, pierce die, and a final bend die.

How are flaws and defects in the steel parts of the Honda Accord detected?

After the parts come out from the press, associates on the back line check and inspect the parts for any flaws and defects.

What is produced in the plastic department of the Honda Accord manufacturing?

The plastic department is responsible for making all the Honda Accord bumpers, boomerangs, and dashboards.

How many different machines are used in the forming department, and what do they produce?

There are five different machines in the forming department. Number five produces the rears, number seven produces the front, number eight also produces the front bumper, number one produces the instrument panels (IPs), and number eleven produces the rear low grade.

What is unique about the welding department in the Honda Accord manufacturing process?

The welding department has over 900 robots, including handling robots, ceiling robots, and welding robots, spread across five areas. It is also one of the most integrated and flexible auto plants in North America.

What are the three innovative areas introduced in the Honda Accord manufacturing process?

The three innovative areas are the inner frame, the roof razor area where the plant is the only Honda plant that does the sunroof model in a brace, and the high-performance adhesive which adds to the rigidity of the body.

What happens to the Honda Accord after it leaves the welding department?

After leaving the welding department, the Honda Accord goes to the paint department where various colors are applied.

What is unique about the 2K primer process used in the Honda Accord's paint application?

The 2K primer is a two-part primer process that uses a resin and a catalyst mixed before application. This is unique to the auto industry and is part of the several processes the car goes through in the paint department.

How long does it take to assemble a Honda Accord after it comes from the weld shop?

It takes an average of about eight and a half to nine hours to assemble a Honda Accord after it comes from the weld shop.

What is the significance of the vehicle quality inspection process for the Honda Accord?

The vehicle quality inspection process includes a human inspection and a computer-led inspection, performing around a 200-check item list while driving the car through the department. This ensures the car's quality and functionality before it is shipped.

What are some of the environmental improvements made at the Marysville Auto Plant where the Honda Accord is manufactured?

The Marysville Auto Plant has made several environmental improvements including the use of high efficiency ovens, air recycling systems, more efficient variable drive motors, a 20 million gallon pond to recycle rainwater, and a new waterborne coating system in the paint shop that reduces emissions of hazardous substances.

Outlines

00:00

🏗️ Manufacturing Process Overview for the Honda Accord

The Honda Accord's manufacturing process begins with rolls of steel that undergo blanking, pressing, and inspection. The steel is cut and shaped through a multi-die process and checked for defects by associates. In the plastic forming department, bumpers, dashboards, and other parts are molded by machines. After this, the Accord moves to the welding department, where over 900 robots perform various tasks, including frame building and the application of innovative adhesives. The welding process enhances structural integrity before the car is sent to the paint department.

05:01

🤖 Assembly and Final Inspection for the Honda Accord

Following welding, the Accord enters the painting and assembly stages. The paint department applies several layers, while additional inspections ensure quality. Robots install the glass with precision using cameras for alignment. Interior components like seats and doors are added, followed by further inspections. The car then goes through an advanced quality inspection process, which includes mass calibration, lock checks, and alignment verification. The vehicle is tested for leaks and rattles before it’s prepared for shipping, ensuring high quality through rigorous testing.

10:09

🌍 New Energy-Efficient Paint Facility and Upgrades at Marysville Plant

In December 2017, Honda completed a $210 million new paint facility at the Marysville plant, designed to be the most energy-efficient of its kind. The new process reduces energy use and emissions, including cutting volatile organic compounds by nearly 66%. Additional investments of $220 million included new welding technology and enhanced production capabilities, preparing for new Honda Accord models. The upgrades included laser brazing systems and an expanded sub-assembly line, bringing more tasks in-house to increase efficiency and product quality.

15:10

🚗 Growth of Honda's Manufacturing Footprint in America

Honda has grown significantly in the U.S. since establishing the Marysville Auto Plant in 1982. The company now operates 12 plants and employs over 25,000 people in America. The Ohio-based plant produces cars, engines, and transmissions, and its capacity has expanded to manufacture millions of vehicles and products annually. By 2019, two-thirds of all Honda and Acura vehicles sold in the U.S. were made in America, showcasing Honda's commitment to local manufacturing and sustainable practices, with facilities emphasizing energy efficiency and environmental impact.

Keywords

💡Roll of Steel

A roll of steel refers to a large coil of steel that is used as the raw material in the manufacturing process. In the context of the video, it is the starting point for the production of a Honda Accord, where the steel is cut and shaped into the components of the car. The script mentions that the steel 'comes in as a roll,' highlighting the initial stage of the car's creation.

💡Blanking Process

The blanking process is a material cutting technique used to shape raw materials into specific forms. In the video, this process is described as the first step where the steel is cut into certain shapes. It is a critical step as it determines the initial form of the car's body parts, setting the stage for further manufacturing stages.

💡Press

In the automotive industry, a press is a machine used to shape metal parts through the application of pressure. The script refers to a 'four die stage press' which includes a draw die, trim die, pierce die, and bend die. These presses are essential in forming the steel into the complex shapes required for car parts, such as the body panels and structural components.

💡Welding Department

The welding department is where the various metal components of a car are joined together. The script highlights that this department has over 900 robots, indicating a high level of automation. Welding is a crucial stage in car assembly as it ensures the structural integrity and strength of the vehicle by joining different parts together.

💡Robots

Robots in the context of the video are automated machines that perform tasks such as handling, ceiling work, and welding. The mention of robots within the welding department illustrates the level of automation in modern car manufacturing, which increases efficiency and precision in the assembly process.

💡Paint Department

The paint department is where the car's body is coated with paint to provide a finish and protect the metal from corrosion. The script describes a multi-step process involving cleaning, sealing, priming, base coating, and clear coating. This stage is essential for the car's appearance and durability.

💡Assembly Line

An assembly line is a manufacturing process where components are added to a product in a sequential manner. The script mentions various stages of the assembly line, such as engine mount, rear suspension mount, and interior parts installation. This process is标志性的 for mass production and is central to the car manufacturing theme of the video.

💡Quality Inspection

Quality inspection is the process of checking the finished product for defects or deviations from quality standards. The video script describes a 'vehicle quality inspection' that includes a computer-led check of around 200 items. This step is crucial to ensure that each Honda Accord meets the company's quality standards before being shipped to customers.

💡Honda Accord

The Honda Accord is a series of automobiles manufactured by Honda, and it is the central product being manufactured in the video. The script details the various stages of its production, from the initial steel roll to the final quality inspection, emphasizing the car's manufacturing process and the attention to detail in its creation.

💡Marysville Auto Plant

The Marysville Auto Plant is a Honda manufacturing facility where the Honda Accord is produced. The script provides background information on the plant, including its location, size, and the range of operations it encompasses, such as stamping, welding, and painting. The plant's description provides context for the setting of the Honda Accord's production.

💡Energy Efficiency

Energy efficiency in the context of the video refers to the plant's efforts to reduce energy consumption and environmental impact. The script mentions new facilities and technologies that save energy, such as high-efficiency ovens and water recycling systems. This keyword is important as it highlights Honda's commitment to sustainable manufacturing practices.

Highlights

The Honda Accord starts as a roll of steel that undergoes a series of manufacturing processes.

Blanking process cuts steel into specific shapes for vehicle parts.

Pressing process includes four die stages: draw, trim, pierce, and bend.

Quality control involves associates inspecting parts for flaws and defects.

Plastic department manufactures bumpers, boomerangs, and dashboards for the Honda Accord.

Forming department operates five machines for different parts of the vehicle.

Welding department features over 900 robots for various tasks.

Innovative areas include inner frame, roof razor area, and high-performance adhesive application.

Paint department applies new colors and finishes to the vehicle.

2K primer process is a unique two-part primer system in the auto industry.

AF (Assembly and Finishing) department installs interior parts and equipment.

Engine and rear suspension mount are key steps in the assembly line.

New glass installation is fully automated with robots for precision.

Final assembly includes installing seats, steering wheels, and doors.

Vehicle quality inspection involves a 200-check item list and computer-aided testing.

Honda Marysville Auto Plant is one of the most integrated and flexible auto plants in North America.

The plant includes operations like stamping, injection molding, welding, painting, sub-assembly, and assembly.

Marysville plant is equivalent to 39 Walmart stores under one roof in size.

Honda invested in overhauling the Marysville plant with new technology and energy-saving measures.

New paint facility uses high efficiency ovens and air recycling systems to save energy.

The plant recycles rainwater for cooling, reducing groundwater usage and energy costs.

Investments in new welding technology and construction techniques for the 2018 Honda Accord.

Honda's manufacturing capabilities in Ohio include 12 plants with the capacity to produce over 1 million automobiles annually.

In 2019, nearly two-thirds of Honda and Acura automobiles sold in the U.S. were made in America.

Transcripts

the honda accord starts out as a roll of

steel that comes in it goes through our

blanking process

which is the materials that cut out to a

certain shape and then goes into our

press through a four die stage press we

have a draw die a trim die a pierced die

and a final bend die as those parts come

out we have associates on the back of

the line that we utilize to check and

inspect the parts for flaws and defects

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here in the formula plastic department

we make all the honda accord bumpers the

boomerangs and the dashboards are made

here in the forming department we have

five different machines that we run

on number five we have the rears

on number seven which we're at right now

we run the front

and then you got number eight you run

the front bumper again and then you run

on number one the ips which is the

instrument panels and on number 11 you

run the rear low grade so you have two

different cord bumpers that you're

running for the rears

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after forming the new accord goes into

our welding department our welding

department has over 900 robots within

those robots we have handling robots we

have ceiling robots and we have welding

robots those robots are within five

areas with inside our department we have

over 800 associates here and over 800

000 square feet with inside our

department so it progresses from our

first zone which does our inner frame

which is new for this accord it is like

the bones with inside the cabin from

that it goes into our next area which

applies the skin from there it goes into

our small parts drawers are installed

and then it goes through our finishing

where

adjustments are made before it gets

shipped off to the paint department

we had started three new innovative

areas this year this is the inner frame

which is the area that we're in now and

also our roof razor area now with inside

our roof raised area we are the only

honda plant that does the sunroof model

in a brace which increases the quality

and appearance of that roof we also have

another innovative which is called our

high performance adhesive which is adds

to the rigidity of the body so those are

the three new additions to this new

accord

after we finish the welding it's off to

our paint department so they can apply

all the new colors

when the accord comes in from out of

weld shop we basically have several

processes we go through we go through a

cleaning process where we go through dip

tank series we send through sealer line

where we seal the body

and make the waterproof we then go

through an inspection process before we

go into the painting booth at that point

we prime

we base coat and we clear coat the body

after it comes out of the oven we do an

inspection process

we put a black wax and an under wax into

the cavities of the car

we put a beta foam in for sound

deadening and we ship the cars to af

once af receives those they take the

doors off

for an offline door process which would

later get married back up to the car

after assembly

once we bring the accords over from weld

shop

it'll take an average of about eight and

a half to nine hours

with the introduction of our new line we

have something that's unique to the auto

industry

which is our 2k primer it's actually a

two-part primer process we have a resin

and a catalyst to get mixed before they

get applied to the car body

after the accord leaves paint it goes

into what you call af on and that's

where all your interior parts get put on

the car like wiring tubing your hvac

your carpets well after the car hits

down this body line it'll approach

toward bumper install then it goes to

engine mount the uniqueness of it is

these process are designed for the

average person to do and they do a lot

of careful studying on process timing

where each unit gets a certain amount of

time to do a process so the next step

for the new honda accord is engine mount

and rear suspension mount

stay up on they will send out a car

that's got a bin number stamped in the

body

once af on receives that information

they'll print out a build sheet

that build sheet gets applied to the

carrier so that every car we know what

what parts go on every car that's got a

model type back at engine rack they will

assign

that engine with that model type to that

build sheet and then

sub assembly will build that engine and

it'll come out here to engine mount and

that's where we'll mount it to the body

we're coming to the end of the assembly

line the new honda accord the tires have

been installed this is all new glass

equipment that was installed it's only

about two years old it's completely

automated when the glass comes down the

robots will pick it up off the carrier

it will take it down set it on a

conveyor it'll be sealed

from there slides down to the robot

picks it up they take it to the car

there are cameras that line that glass

up so for a correct fit and then the

robots will apply the glass to the body

after we install the windshields we'll

go down start installing interior parts

front and rear seats will be installed

steering wheels we install the front and

rear doors that's winding up the

assembly then we go into more inspection

this is the last step for the new honda

accord these units go through the paint

area they paint the doors then they

remove them from drop lift

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sends the doors down the door line where

they assemble the door they install the

liner the door handles the mirrors the

chrome and this area right here is

installed and this is where we install

all four doors for the new honda core

unit and now we are ready for vehicle

quality inspection vehicle quality

inspection is a human inspection along

with a computer led which stands for

line in tester and it's going to perform

around a 200 check item list while we're

driving the car through our department

first thing the car goes through is what

we call mass calibration that sets up

the radars and the cameras and our car

for the new technology cars the honda

put out this model here

next after the car leaves the mass

station it'll go down through our

exterior and lock function check they're

checking gaps on doors they're checking

closing force of your trunks your

bonnets your closing force of your doors

your child locks your seat belt safety

latches after the car goes from there

the car will go into our dyno area our

dyno will set the front and rear

alignment for the car

check a lot of the features as far as

cruise control to get ready to take the

car outside

through a shower tester booth it puts uh

185 gallons of water a minute on the car

placed in the car in assembly is little

cardboard strips in the low lying points

of the car anything that would leak the

water would end up on that cardboard

strip

also while we're outside we go down a

squeak and rattle track that's

specifically designed to bring out

different rattles in our cars suspension

rattles interior cabin rattles

anything that the driver might come

across we have a booth that's designed

to actually recreate that track out

there and that track will recreate that

noise and allow us to find the noise and

then of course it's always a matter of

checking the 10 cars before that car and

the 10 cars behind that car so we can

guarantee our quality

and then back into another final

inspection area before the car is taken

to pre-ship honda marysville auto plant

is a honda manufacturing facility

located approximately six miles

northwest of marysville ohio and 42

miles northwest of columbus near the

intersection of the united states 33 and

state route 739

it is one of the most integrated and

flexible auto plants in north america

operations include stamping classics

injection molding welding painting

sub-assembly and assembly the assembly

plant opened in 1982.

marysville plant is equivalent in size

to 39 walmart stores under one roof

honda overhauled the marysville plant

over several years one department after

another without losing a day of

production

during overhaul honda replaced old

hydraulic welding systems designed for

specific models with programmable

electronic welding robots that can weld

different vehicle body types for better

flexibility and higher productivity work

started in 2002 in advance of the launch

of the 2003 honda accord in 2004 honda

commenced work on a 234 000 square foot

extension of the plant for a new paint

facility of 123 million dollars

the new facility uses high efficiency

ovens air recycling systems and more

efficient variable drive motors that

would save 34 energy the company also

built a 20 million gallon pond behind

the plant to recycle rainwater for

helping to cool the plants

by recycling runoff from parking lots

and roofs the seven acre pond system

would significantly reduce the use of

groundwater and save energy cost the new

fully automated paint shop which can

paint 1 000 vehicles a day was opened in

january 2006.

it uses a new waterborne coating system

with 84 modemin robots that reduces

emissions of hazardous substances by 41

percent

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in december 2015 construction of the new

paint shop for line 1 began costing 210

million dollars the new facility has an

annual capacity 229 000 units when

completed in december 2017 it would be

the most energy efficient paint line of

the company's auto production network in

united states and add 300 000 square

foot to marysville plant it replaces a

facility built in 1985. auto body

painting can account for upward of 60

percent of an auto plant's total energy

use therefore cutting its energy use

would have a significant environment

impact the new facility uses a more

compact and energy efficient four coat

to bake short process eliminating one

primer co-curing oven the new paint

process reduces volatile organic

compounds emissions by nearly 66 percent

honda invested 220 million dollars in

mary's fill plant including an all-new

welding shop with 342 new robots for 165

million dollars to prepare for the new

inner frame construction technique for

the 2018 honda accord the new high

volume laser brazing system joins the

roof to the body side panels precisely

that it eliminates the black plastic

garnish many sedans used to cover the

ring channels honda also expanded rear

door line production capability to

accommodate dropping the coupe from the

lineup for model year 2018 brought in

house the sub-assembly of front-end

module civic court and added a new

sub-assembly for the intelligent power

unit which consists of the battery pack

and its control systems for the 2018

accord hybrid

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established in 1982 the marysville auto

plant with two production lines is

honda's largest vehicle production

facility in the country in 1989 honda

added a second auto plant in ohio the

east liberty auto plant the company

began ohio production of the acura nsx

supercar in 2016 at its newly

established performance manufacturing

center in marysville hondo also builds

engines and transmissions in ohio at the

companies and of engine plant and honda

transmission manufacturing of america

over the course of four decades honda

has steadily grown its manufacturing

capabilities in the region honda now

employs more than 25 000 associates at

12 plants in america with the capacity

to produce more than 1 million

automobiles 3 million engines four

hundred thousand power equipment

products and three hundred thirty

thousand power sports products each year

using domestic and globally sourced

parts

in 2019 nearly two-thirds of all honda

and acura automobiles sold in the united

states were made in america

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