Front end assembly procedure volvo trucks

Department Reference #

Confirmed By Process Owner Date Chapter Rev. PageIssuer

Front End Assembly - 21222124

31Julian Kalac QA Manager02/24/14

• Problem: Customer (Volvo) 8D several

reoccurring quality issues 1. Missing front plate, not assy

11 defects in 3 different shipments over 1 month period.

No Assy instructions.

Solution: Develop SOP using Assy drawing and

POKE YOKE the Assy process with Red/Green Light

visual and Air cut off

RESULTS: ZERO DEFECTS 8 shipments (4 months)








1Ju 7Front End Assembly Cell

20904633

FRAME

EXTENSION

FRONT

DIAGRAM 5

STEP #9 FIT THE OTHER FRONT FRAME EXTENSION (20904633)

INTO PLACE ON TOP. (REF. DIAGRAM 5)

CAR M310330ASSEMBLY








1Production Improvement Team 1

CAR M310330ASSEMBLY

Front End Assembly Cell

21125557

RH FRAME

EXTENSION

21125555

LH FRAME

EXTENSION

27QL299M

(25176484)

TOW HOOK

RIGHT HAND

27QL299M2

(25176483)

TOW HOOK

LEFT HAND

STEP #1 - PLACE THE LEFT AND

RIGHT HAND FRAME EXTENSIONS

ONTO THE FIXTURE ON THEIR SIDE

AS SHOWN IN DIAGRAM 1.

STEP #2 - INSERT THE INDICATED

TOW HOOK INTO EACH SIDE.

PLACE THESE WITH THE HUCK

SPIN BOLTS ALREADY IN PLACE, INTO

THE HOLES IN EACH FRAME

EXTENSION. (4AM23 IS A LONGER

HUCK SPIN BOLT AND IS PLACED

CLOSEST TO THE CURVE IN THE

HOOK. THE UPPER HUCK SPIN BOLT

IS 4AM22) REFER TO DIAGRAM 2

4AM22

(25164087)

HUCK SPIN

BOLT4AM23

(25166332)

HUCK SPIN

BOLT

DIAGRAM 2

DIAGRAM 1




31Julian Kalac QA Manager02/24/14Front End Assembly Cell

159AM3

HUCKSPIN COLLAR

STEP #3 - PLACE 1 HUCK SPIN COLLAR (159AM3) ON EACH HUCK

SPIN BOLT THREADED THROUGH THE TOW HOOKS

(REF - DIAGRAM 3)

STEP#4 - TIGHTEN ALL 4 HUCK SPIN COLLARS USING

THE HUCK BOLT GUN.

DIAGRAM 3

159AM3

HUCKSPIN COLLAR

CAR M310330ASSEMBLY

2








21 3Front End Assembly Cell

CRITICAL COMPONENT 21125482 FRAME EXTENSION FRONT

STEP #5 - STAND THE FRAME EXTENSION

21125557 UP, AND PLACE ON THE LOCATING

PINS OF THE FIXTURE.

STEP #6 - FIT THE FRONT FRAME EXTENSION

(21125482) INTO PLACE WITH THE RH FRAME

EXTENSION (21125557) (REF. DIAGRAM 4)

STEP #7 FIT THE FRONT FRAME EXTENSION

(21125482) INTO PLACE ON THE LH FRAME

EXTENSION (21125555)

STEP #8 PLACE LH FRAME EXTENSION ONTO

THE LOCATING PINS ON THE FIXTURE.

DIAGRAM 4

CAR M310330ASSEMBLY





CRITICAL COMPONENT 21125482 FRAME EXTENSION FRONT. RED light normally ON. If

missing component, RED light will remain ON and air is shut-off.

POKE YOKE CHECK --> IF

COMPONENT IS NOT PRESENT, CANNOT

TORQUE THE BOLTS (SHUT-OFF VALVE)

4Front End Assembly Cell





Lift the Front End Extension and place it on the spacer bar to assist with assembly of the LH

side. The spacebar activates the sensor and rhe light turns GREEN






ASSEMBLED FRONT END EXTENSION










STEP #10 INSERT THE SPACER BAR ONTO THE ASSEMBLY AS SHOWN ABOVE

TO STABALIZE THE PART.

RELIABLE METHOD: HOLES ON THE SPACER BAR

MUST LINE UP WITH THE HOLES ON THE FRAME

EXTENSIONS.

CAR M310330ASSEMBLY









STEP #11 INSERT 1 FLANGE SCREW (27AM99) PER SIDE THROUGH THE

INDICATED HOLE IN 21125482 AND EACH FRAME EXTENSION.

STEP #12 SECURE EACH FLANGE SCREW BY HAND USING 1 FLANGE

LOCK NUT EACH.(191AM13)

CAR M310330ASSEMBLY









VIEW FROM

BACKSIDE

OF ASSEMBLY

STEP #13 INSERT 2 FLANGE SCREWS (27AM99) PER SIDE

THROUGH THE FRONT FRAME EXTENSION AND THE LH AND

RH FRAME EXTENSIONS.

STEP #14 SECURE THESE 4 FLANGE SCREWS BY HAND

USING 1 FLANGE LOCK NUT PER SCREW (191AM13)

FRONT VIEW OF ASSEMBLY

CAR M310330ASSEMBLY









1 PER SIDE OF

191AM13 - 981040 - NUT

27AM131 - 975209 - BOLT

IN SAME LOCATION EACH SIDE

CAR M310330ASSEMBLY









STEP #15 INSERT 2 FLANGE SCREWS (975204) PER SIDE THROUGH THE FRONT FRAME

EXTENSION AND THE LH AND RH FRAME EXTENSIONS. (REF. DIAGRAM 6 BELOW)

STEP #16 SECURE THESE 4 SCREWS BY HAND WITH FLANGE NUT 976432

12

DIAGRAM 6

CAR M310330ASSEMBLY









27AM99 - 975121 - BOLT

191AM13 - 981040 - NUT

975204 - BOLT

189AM16 - 976432 - NUT

BOLT PLACEMENT DIAGRAM

CAR M310330ASSEMBLY









STEP #17 PLACE THE APPROPRIATE

EXTENSION ON THE TORQUE GUN.

STEP #18 WITH MINIMUM TORQUE,

TIGHTEN THE TWO SCREWS

(27AM99) THAT WERE PREVIOUSLY

PLACED INTO THE TOP OF THE

ASSEMBLY TO SECURE THE

20904633 TO THE RH AND LH

FRAME EXTENSIONS.

RELIABLE METHOD

FLANGE SCREW 975209 IS

SECURED FIRST TO AVOID

FURTHER MOVEMENT OF

THE ASSEMBLY WHILE TIGHTENING

THE OTHER SCREWS

STEP #19 TIGHTEN ALL OTHER SCREWS

WITH MINIMUM TORQUE SO THEY ARE

NUT RUNNER TIGHT.

STEP #20 REMOVE THE SPACER BAR

STEP #21 LOAD PART ONTO SKID

USING THE HOIST.

COMPLETED PART

CAR M310330ASSEMBLY





CAR M310330ASSEMBLY

Front End Assembly Cell

Engineering

Front end assembly procedure volvo trucks