SOP Manual for Light Truck and Utility Vehicle Manufacturing


The Light Truck and Utility Vehicle Manufacturing Industry is primarily involved in the manufacturing of either chassis and body or only chassis of Light Truck and Utility Vehicles. The vehicles falling under the industry include minivans, sport utility vehicles, pickup trucks and light duty vans.

The Department of Industries coming under The Light Truck and Utility Vehicle Manufacturing Industry are:-

  • Assembly plants, light trucks on chassis of ownmanufacture
  • Assembly plants, mini-vans on chassis of ownmanufacture
  • Assembly plants, sport utility vehicles on chassis of ownmanufacture
  • Cab and chassis, light trucks and vans,manufacturing
  • Chassis, light truck and utility,manufacturing
  • Light utility trucks assembling on chassis of ownmanufacture
  • Minivans assembling on chassis of ownmanufacture
  • Motor homes, self-contained, mounted on light duty truck chassis of own manufacture
  • Pick-up trucks, light duty, assembling on chassis of ownmanufacture
  • Sport utility vehicles assembling on chassis of ownmanufacture
  • Trucks, light duty, assembling on chassis of ownmanufacture
  • Vans, commercial and passenger light duty, assembling on chassis of own manufacture

The Manufacturing process begins at the body shop where front structure of the vehicle. The radiator support, two side rails and clips on the side rails for the bumper structure are first placed. This front structure built in the body shop is put on the automated conveyor line. Simultaneously robotic arms weld the ladder assembly which acts a backbone support to the floor and sides of the vehicle. It also contains  the pockets that hold the seats. Then the same robotic arms weld the frontal structure and the ladder structure together.


Meanwhile one panel of large galvanized steel is used to make the passenger body. This process is also automated and is standard for the model. The robots attach reinforcements to the panel, so that the interior finishing and other components can be added. A transfer device swoops down and transfers panel to the next station. The drivers side body panel is also similarly welded and made by the robotic arms. It is also taken to the next station by the transfer device.

The floor panel and the floor assembly mentioned earlier are put together. Robotic arms weld the side panels to the under panel. The inner wheel welds are attached to the side panel. Then the roof is welded. Then the welded structure moves in to closures. In the closures, the lift-gate, the hood and the doors are attached. Then the engine assembly is carefully fixed. The engine assembly can either happen In-house  or be directly derived from a supplier. Then the structure goes to the paint shop and then the trim shop. The necessary glass,handles and interior components are fixed in the trim shop.

In the Chassis Department the engine,transmission, the rear suspension and the brake assembly are installed from underneath. This assembly section has two tiers. The van on top and the chassis assembly in the bottom. The Gas tank is hooked up manually. Then the seats are clamped at the seat pockets. Tire is attached to the wheel rim which is then inflated and balanced. With this the assembly is complete.

The Machineries used in The Light Truck and Utility Vehicle Manufacturing Industry are:-

  • Conveyorbelt
  • Weldingrobot
  • Paintingrobot
  • Bin transportrobot
  • Overheadconveyor
  • CNCmachine
  • Jigwelder
  • Engine machiningstation
  • Airwrench
  • Spotwelder
  • Automatic partsfeeding
  • Automated assemblysystems
  • Feature checking systems
  • Various inspectionsystems
  • Gauging andmeasuring
  • Adhesive application cells
  • Ultra sonicwelding
  • Infra-redwelding
  • Drilling and tappingmachines
  • Cuttingmachines
  • Prototype machining
  • Small batchmachining
  • Large scalemilling
  • Assembly Jigs andFixtures
  • Intelligent InspectionFixtures
  • Specialist FormTooling
  • Quick Change Tooled Assembly Fixtures
  • Robot WeldTooling

International Standards for The Light Truck and Utility Vehicle Manufacturing Industry are:-

The International Associations for The Light Truck and Utility Vehicle Manufacturing Industry are:-

World’s Top Companies in The Light Truck and Utility Vehicle Manufacturing Industry are:-

Magazines and Journals For The Light Truck and Utility Vehicle Manufacturing Industry are:-

SOP Manual for Light Truck and Utility Vehicle Manufacturing

Research By : Aadithya

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