3rd-gen Hyundai i20's manufacturing process detailed in video

The new i20 uses 66% Advanced High-Strength Steel in its construction.

Hyundai has released a new video that details the complete manufacturing process of the third generation i20.

The new i20 uses 66% Advanced High-Strength Steel in its construction. The superstructure is created using a 5,400 tons stamping press. Hyundai uses Crack, Neck Prediction methodology to produce zero crack panels. High quality grade coils are used to shape the panels, while 3D scanning is used to analyse and strengthen the press panel parts accuracy and precision.

The pressed panels are then sent to the body shop, where 450 4th gen robots apply over 4,000 welding spots in each car. More than 70 cars are processed here every hour. The process is divided into three stages -

• Intelligent weld monitoring
• Real time weld quality confirmation system [Colour tip sensor]
• Real time sealer quality confirmation system

The finished body is then sent to the paint shop. This is where High Throw Power 7th Generation Electro Deposition Paint is applied using 72 robots. An Anode Cell Current Monitoring system enhances the pain application quality.

Hyundai's in-house Endurance lab tests the performance with load conditions for 849 hours and without load conditions for 5 lakh cycles for transmission systems and over 350 hours for the Engine system. A Cold Test Bed tests engines for more than 15 parameters without burning fuel. All engines have to go through this automated test before being mounted in the vehicles. Both petrol and diesel engines are built at the powertrain shop using 700 CNC machines with Integrated SPC (Statistical Process Control). 58 engine parts are verified with High Speed Vision (60 frames/ minute).

80% of the car’s parts are fixed, preparing it through a 100% systemized 3 stage dynamic tightening confirmation that features:

• Electric tool tightening 700+ dynamic joints per car (safety and critical parts)
• Re-confirmation system across all the line (Trim, Chassis and Final line)
• Tightening quality and Sign-off interlock to ensure zero defect vehicle rollout

A systemized part feeding method is used for maintaining quality in feeding and assembly operation using:

• Global Part Traceability Information System
• Advanced Part Management System
• Mobility Sequence Feeding System
• Trolley Scheduling System

A 324-point check in HIDIS (Hyundai Integrated Digital Inspection System) ensures quality standards are maintained. Every vehicle is inspected by over 500 quality in-charge experts. The car then undergoes a dynamic road test on 18 drive tracks. The car is put through a leak test that is equivalent to driving through rain that exceeds the heaviest recorded monsoons, with a shower condition of 60 mm per minute or 3,600 mm per hour at a pressure of 3 bar.