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FORD OTOSAN

Body & Assembly Shops

Equipment Information Document

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Sale Package

The package to be sold is composed of:

• 3 pairs of symmetrical full-automated vehicle bodyside lines

• 2 different full-automated complete vehicle body framing lines,

• 1 semi-automated vehicle underbody line,

• Manual weld guns,

• Several material handling equipments and conveyors (Body &

Assembly)

• Miscellaneous/unique equipments.

Contents

1. Body Shop

1.1. Framing 1

1.2. Framing 2

1.3. Bodyside 1 (Left)

1.4. Bodyside 1 (Right)

1.5. Bodyside 2 (Left)

1.6. Bodyside 2 (Right)

1.7. Bodyside 3 (Left)

1.8. Bodyside 3 (Right)

1.9. Underbody

1.10. Manual Weld Guns

1.11. Miscellaneous/Unique equipments

2. Assembly Shop

2.1. Skillet Conveyors

2.2. EMS Carriers (for windscreen assembly)

2.3. Body Overhead Conveyor Systems

2.4. Engine Assembly And Mounting Dollies

2.5. Engine Assembly Dollies

2.6. Fluid Filling Stations

2.7. End Of Line Lift and Conveyor

1. BODY SHOP

1.1. Framing 1

Lay-Out

Specifications

Number of stations 17

Number of robots 33

Line capacity (actual) 31 veh/hour

Conveyor type Independent power roller bed conveyor system

Process summary • Spot welding of underbody, right&left bodysides and roof structure

(geometry and respot)

• Automated underbody floor drilling operations

• Additional manual MAG welding operations in closed cabinet.

1.1. Framing 1

Visuals

1.1. Framing 1

Major Equipments

Item Model Count

Comau Robot See next page for details 33

Robotic Spot Weld Gun Sciaky / ARO 40

Robotic Sealer Unit SCA 3

Tool Changer Walther-Präzision 32

Electrode Changing Machine (Elektrodmak) - 11

Electrical tip dresseer AEG 32

Turn Table - 1

MAG Welding Machine - 7

1.1. Framing 1

Robot Details

1.2. Framing 2

Lay-Out

Specifications

Number of stations 7

Number of robots 11

Line capacity (actual) 19 veh/hour

Conveyor type Independent power roller bed conveyor system

Process summary Spot welding of underbody, right&left bodysides and roof structure

(geometry and respot)

1.2. Framing 2

Visuals

1.2. Framing 2

Major Equipments

Item Model Count

ABB Robot See next page for details 10

Comau Robot See next page for details 2

Robotic Spot Weld Gun Nimak 12

Tool Changer Walther-Präzision 22

Electrical tip dresseer AEG 15

Lift Turn Table - 1

MAG Welding Machine - 7

1.2. Framing 2

Robot Details

1.3. Bodyside 1 (left)

Lay-Out

Specifications

Number of stations 6

Number of robots 11

Line capacity (actual) 30 parts/hour

Conveyor type Lift shuttle in linked lines

Process summary Spot welding of left bodyside inner and outer panels (geometry and

respot)

Visuals

1.3. Bodyside 1 (left)

Major Equipments

1.3. Bodyside 1 (left)

Item Model Count

Comau Robot See next page for details 11

Robotic Spot Weld Gun Sciaky 12

Robotic Sealer Unit SCA 1

Tool Changer Walther-Präzision 4

Electrode Changing Machine (Elektrodmak) - 6

Electrical tip dresseer AEG 9

Robot Details

1.3. Bodyside 1 (left)

Sealer Robot Details

1.4. Bodyside 1 (right)

Lay-Out

Specifications

Number of stations 6

Number of robots 11

Line capacity (actual) 30 parts/hour

Conveyor type Lift shuttle in linked lines

Process summary Spot welding of right bodyside inner and outer panels (geometry and

respot)

Visuals

1.4. Bodyside 1 (right)

Major Equipments

Item Model Count

Comau Robot See next page for details 11

Robotic Spot Weld Gun Sciaky 12

Robotic Sealer Unit SCA 1

Tool Changer Walther-Präzision 4

Electrode Changing Machine (Elektrodmak) - 7

Electrical tip dresseer AEG 10

1.4. Bodyside 1 (right)

Robot Details

Sealer Robot Details

1.4. Bodyside 1 (right)

1.5. Bodyside 2 (left)

Lay-Out

Specifications

Number of stations 4

Number of robots 6

Line capacity (actual) 13 parts/hour

Conveyor type Lift shuttle in linked lines

Process summary Spot welding of left bodyside inner and outer panels (geometry and

respot)

Visuals

1.5. Bodyside 2 (left)

Major Equipments

Item Model Count

ABB Robot See next page for details 6

Robotic Spot Weld Gun Nimak / ARO 8

Tool Changer Walther-Präzision 8

Electrical tip dresseer AEG 8

Lift shuttle - 1

Robotic Sealer Unit SCA 1

1.5. Bodyside 2 (left)

Robot Details

1.5. Bodyside 2 (left)

1.6. Bodyside 2 (right)

Lay-Out

Specifications

Number of stations 4

Number of robots 5

Line capacity (actual) 13 veh/hour

Conveyor type Lift shuttle in linked lines

Process summary Spot welding of right bodyside inner and outer panels (geometry and

respot)

Visuals

1.6. Bodyside 2 (right)

Major Equipments

Item Model Count

ABB Robot See next page for details 6

Robotic Spot Weld Gun Nimak / ARO 8

Tool Changer Walther-Präzision 8

Electrical tip dresseer AEG 8

Lift shuttle - 1

Robotic Sealer Unit SCA 1

1.6. Bodyside 2 (right)

Robot Details

1.6. Bodyside 2 (right)

1.7. Bodyside 3 (left)

Lay-Out

Specifications

Number of stations 7

Number of robots 17

Line capacity (actual) 26 parts/hour

Conveyor type Lift shuttle in linked lines

Process summary Spot welding of left bodyside inner and outer panels (geometry and

respot)

Visuals

1.7. Bodyside 3 (left)

Major Equipments

Item Model Count

Kuka Robot See next page for details 17

Robotic Spot Weld Gun Nimak / ARO 18

Tool Changer Walther-Präzision 12

Electrical tip dresseer AEG 16

Electrode Changing Machine (Elektrodmak) - 14

Lift shuttle - 1

Robotic Sealer Unit SCA 4

Robotic Gripper Unit - 1

1.7. Bodyside 3 (left)

Robot Details

1.7. Bodyside 3 (left)

Sealer Robot Details

1.8. Bodyside 3 (right)

Lay-Out

Specifications

Number of stations 7

Number of robots 18

Line capacity (actual) 26 veh/hour

Conveyor type Lift shuttle in linked lines

Process summary Spot welding of right bodyside inner and outer panels (geometry and

respot)

Visuals

1.8. Bodyside 3 (right)

Major Equipments

Item Model Count

Kuka Robot See next page for details 18

Robotic Spot Weld Gun Nimak / ARO 18

Tool Changer Walther-Präzision 12

Electrical tip dresseer AEG 16

Electrode Changing Machine (Elektrodmak) - 14

Lift shuttle - 1

Robotic Sealer Unit SCA 4

Robotic Gripper Unit - 1

1.8. Bodyside 3 (right)

Robot Details

Sealer Robot Details

1.8. Bodyside 3 (right)

1.9. Underbody

Lay-Out

Specifications

Number of stations 6

Number of robots 1

Line capacity (actual) 23 parts/hour

Conveyor type Semi-automatic lift shuttle in linked lines + chain conveyors

Process summary Spot welding of underbody frame and floor pan

Visuals

1.9. Underbody

Visuals

1.10. Manual Weld Guns

Item Count

ARO 191

PW 181

Nimak 7

Visuals

1.11. Miscellaneous/Unique equipments

Specifications

Laser Cutting Booth (with 1 robot & source) OEM Robot: KUKA, LASER: Trumph, Cutting Head: Precitec Age: 2008 Booth Dimensions: 7,0 m x 5,0 m x 4,2 m

*One of the robots is not included into the sale package.

Visuals

1.11. Miscellaneous/Unique equipments

Specifications

Automatic Stud Weld Station (2 robots with t-stud units & turn table) OEM Manipulators: ABB IRB 6400/2.4-150, ABB IRB 6400/2.8-120 T-Stud Units: Tucker Age: 2000

T-Stud Units Manipulator&Controller Automatic Stud Station

Visuals

1.11. Miscellaneous/Unique equipments

Specifications

Pedestal Weld Machines (6 items) OEM Machine Type: Coşkunöz (Turkey) Age: 2000

2. ASSEMBLY SHOP

2.1. Skillet Conveyors

Visuals

Specifications

Number of items 52

Dimensions 6000 mm x 2800 mm x 450 mm

Notifications • Periodically controlled.

• Currently in use

2.2. EMS Carriers (for windscreen assembly)

Specifications

Number of items 2

OEM Daifuku (Japan)

Notifications • Electirified monorail system with vacuum generators

• Automatic elevation and manual windscreen assembly

Visuals

2.3. Body Overhead Conveyor Systems

Specifications

Number of items 29

OEM Daifuku (Japan)

Notifications • Vertical adjusting conveyor

• Maximum payload capacity: 1291 kg (work capacity)

Visuals

2.4. Engine Mounting Dollies

Visuals

Specifications

Number of items 6

OEM Daifuku (Japan)

Notifications • Payload capacity (incl. Tooling plate): 450 kg

• Superstructure: Hydraulic scissors lift with tooling fixture

2.5. Engine Assembly Dollies

Visuals

Specifications

Number of items 22

OEM Daifuku (Japan)

Notifications • Payload capacity (incl. Tooling plate): 350 kg

• Track length: 19,635 m

• Plate pitch: 800 mm – Work pitch: 2400 mm

2.6. Fluid Filling Stations

Visuals

Specifications

Number of items 4

OEM Dürr – Schenck (Germany)

Notifications • Windscreen washer water, coolant fluids, air conditioning gases

and brake fluid filling combined

2.7. End Of Line Lift and Conveyor

Visuals

Specifications

Number of items 1

OEM Daifuku (Japan)

Notifications • Vertical lift

• 2(600) x 91400 mm double slat type end of line chain conveyor.

• Pitch: 6000 mm

Contacts

Sale, Operation and Logistics Issues

Ayhan Kalkavan – Managing Director, Global Industry

ayhan.kalkavan@global-industry.net

Sedat Demir – Sales&Marketing Director, Global Industry

sedat.demir@global-industry.net

Kemal Karakaş – Operations&Logistics Director, Global Industry

kemal.karakas@global-industry.net

Technical Issues and Package Content Details

For Body Shop Content,

Gökan Acar – Maintenance Engineer, Ford Otosan

gacar1@ford.com.tr

For Assembly Shop Content,

Murat Doğan Ercan – Automation&Projects Engineer, Ford Otosan

mercan1@ford.com.tr