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Manufacturing and Modifying Processes of Kits or External Body Parts of a Car (Part 04)
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Golam Moula Mondal
This is Md. Golam Moula Mondal. I have completed BBA (Major in Finance and Banking) from Patuakhali Science and Technology University. 
By Golam Moula Mondal
Published on 24 October 2012
 
Manufacturing and Modifying Processes of Kits or External Body Parts of a Customized Car. Phases in product design and development. Quality Assurances.

Manufacturing and Modifying Processes of Kits or External Body Parts of a Car

Chapter-05
5. PRODUCT SERVICE OVERVIEW

As we are producing and modifying at the same time, we would charge differently for manufacturing and modifying. The vehicles that we would be working on could rage form sedan to SUV. For any sort of vehicles, we can have the same procedure and treatment underlying the manufacturing or modifying processes. The manufacturing process is created to produce the following kits or external body parts that could be fitted along side the following parts of the body of a customer's car:

5.1    Front side
Bonnet: Typically a customer might want to replace a bonnet of carbon fiber that is lighter than the original tin body. But this is an expensive replacement. We could make a substitute that would seem like carbon fiber but won't be as light as that of the real one but is undistinguishable by the naked eye. Other than that, we would also insert various models and designs of vents and grills on the bonnet for further modification.

Roof vent: Some cars might have run roofs and some cars might not. In any case, we can modify or produce different vents or sculptures of different designs that would go with the car according to the preference of their owners.

Head lights: many car owners would like to have head lights of other cars and brands that they might think would make their cars look unique. Some might really like the head lights of another branded car that he/she cannot afford. But we can actually reshape the socket of their headlights and craft it in the shape of their desired headlights of practically any car.

Wiper vent: Through our technique of restructuring and modifying, we can create larger and wider vent for the wiper section. We can produce a wider and larger wiper vent and fir it on a car according to the preference of the customer. The fiber that we would use to replace the original is would be as good as the original if not better.

Front Grill: by having a different grill in the front side of the car can make drastic changes to a car. This is one of the easiest ways of modifying a car. The grills that are original do not have many designs to take notice. We could change that by designing extra hedged grills and perforations or even lesser than the original and also reshape it to give a car a unique look.

Front fender: the front fenders of a car are usually plain and simply consternated. We could reshape the fender or create a newer one depending on the changes needed to fit the customers demand. Manufacturing a fender will require most use of raw materials and would be more expensive that the others. But replacing a fender will certainly give a lighter weight, however making the car weaker than that of before, since fiber would be thinner and weaker than tin.

Front kit bumper: to keep a low profile some customers would want to have dashing and almost touching the road bumpers on their cars. Some would want extravagant designs as well. All of these could be done in creating the perfect set of front kit bumpers as well as the rear one.

Front lip: the front lip of a car is the extra piece of body attached to the front bumper of a car. This could vary a lot in shape and sizes depending on the bumper itself. It is recommended that customers would change the bumper as well as the lip since the materials would he the same for both and we could give a better finishing touch to make them look made for each other. There would be packages in which they would be sold.

Mud guard: the mud guard is the rubber plate tat sticks out from both ends of the tire gap that would prevent mud or water to splash on to the body of the car below. The mud guards are attached to a piece of a fiber that holds them with the body of the car. We could change the fibers into bigger and more attractive ones to enhance the look of the wheels of a car.

Bumper Grill: the bumper that we can change can have different styles of grills attached to it for producing more vents for passing air and thus reduce air friction. This has been stated by the aero-dynamics intelligence. By having more designs for this service we can increase the demand for this category of product.

5.2    Both sides of a vehicle

Window sill vent and beat: the windows on which they are affixed are the sill and the beat is what holds them firm to their roots. The outlook of these fibers can be changed to give them amore highlighted look.

Rear fender: the rear fenders are the body parts themselves and need most use of raw materials as well as the front fenders. In fact they might need more than that of the front fenders. They can be.designed in various forms and ways as well. For only modifications, the existing fenders can be engraved and heated and hammered and cut to form vents and grill sand other sorts of stylish air collectors.

Door: there is a massive and very delicate process to manufacture something for the doors since they are always handled. We take extreme care with the fitting and finishing so that no problems in falling off or damage control persists.

Side skirts: just like the front/rear bumpers and their lips attached to them, these side skirts are the ones on the sides almost on the foot rest outside the vehicle. The main focus in these side skirts is that they need to be as low as the bumpers on both sides' front and rear so that the entire car is kept to be of a definite depth and lowness (low profile) all around it.

Handle bars: the handles are mainly plastic which could be replaced by thick fiber, but this process is very tricky since the dice required for this is very small. This option will not be given to customers as a single job but rather it will be a package if the customer remodels over 4 parts of his/her car.

5.3    Rear side

Hood: the hood might contain subwoofers and other stereo systems that might need exposure since they might be kept in the hood. We can design the perforations of the hood and even manufacture new ones to affix on t the existing hood for better support and firm hold.

Vent: the vent of the hood is small scale and requires very less raw materials. The dice what would be required for this would be the vents for all sides. So that one car would have the same kind of vent all around.

Rear window sill: the rear window sill would just be like the same as the front sill except the grill would be smaller.

Spoiler: the spoiler is the most highly demanded items of all. There would be more than a thousand existing shapes and sizes for this type of kit. As usual, since this is a big part of the body that is extra, and used for aerodynamics, care must be taken while fitting it on the car.

Rear lights socket: just like the front light or head lights socket these sockets could also be changed to fit any sorts of lights that is desired. We would not obviously provide them with the lights though.

Rear kit bumpers: these have to resemble the front kit bumpers as well. They the low profile of thee the two should be the same.

Rear lip: the lowest part of the rear bumper.

Rear grill: grills can be of many types for the rear bumper. As long as it is made or even modified, the grill needs to be fitted o to the car before the bumper is fitted on.

Rear mud guard: a clip that would hold the mud guards. Similar to the front mud guards if not identical.

5.4    Facilities:

Band: we take lease of a total of 4000 square feet of land in Banani and make that our show room and headquarters. The other piece of land totaling about 5000 sqquare feet would be taken lease in Rampura Biswaroad where we would place our factory. The distance of space between the office and the factory is very near that would help us faster the delivery system.

Employees: the detailed organogram and the structure of our organization with the number of employees are all given in the Human Resource section of this business plan.

5.5    Equipment and Machinery:

Welding machine: the welding machine is used for any activity where there is the call for lead to lead adhesion. Since the fiber is mostly used to connect with the car through the aid of glue and repeating, welding need not be used there. The grills, vents and other types of small parts of the car need to be welded on to metal grills or nets for a ravishing look.

Heating chamber: an oven of rather big size is required for melting the dice and ready to be reshaped into the desired size and structure.

Chisel: for cutting and hedging the dice these types of chisels are required to give the exact shape and definition of the final product. It is very important for our sculptures to do this job with time since this is the process for converting the designs in the computers to reality.

Hammer: also a kind of instrument that is used alongside the chisel. The engineers are able to work their shape and sizes with these tools.

Paint mixer: the job of the paint mixer is to mix the paint in such a way that the desired color that the customer chooses can be extracted properly. There would be a wide variety of color variation any way the customer may want and this is accomplished through computer software color base. We would be using a certain brand called FIKKINS of which we would also be buying pudding and other raw materials from as well. Getting the painting job done depends on how well we have mixed the paint. Thus this machine is essential to ad value to our finished product as we fit it on to the car of the customer.

Dice Maker/ Molder: the molder is a large machine which needs constant check by the engineers as it is responsible of making the dice in which we would ultimately make our product. The design starts from here. The integrated design is converted into making the dice and further analyzed to check if the final product will come out as good as it seemed in the computer.

Spray Machine: the paint that we would mix and spray on to the following made body part or in most cases the entire body itself, would need to have an efficient way of spraying. The painting job requires a lot of time depending on the skill of the painter and the technology of the painting machine. We have decided to buy the state of the art pint sprayer that would be maintained and washed properly with grease and oil to avoid rusting in the cylinders. This would also make our work much efficient and reduce the lead time for the following process which is the polishing and waxing.

Finishing tools: these are the basic types of tools that would be used manually by labors and engineers who would be working together with a team and a group leader. They would integrate tier work in to one single goal and perhaps for one product or simultaneously a few products depending on the rush of the assembly line. This is the final stage before the painting is done therefore great team work and perseverance is required for this.

Grinder: the grinder machine is required right after the process of volume measuring is done. For the mixing panel to work well it is essential that the grinding takes place without any flaws. Since the raw materials are mainly fluid and but might contain slid particles for extreme cold storage reasons. This will be over come by the grinding process. We have chosen our grinder machine to be of state of the art and will have a variety of options for variable speed of blending as per the volume of raw materials that we use per unit of product.

Volumetric measurer: measuring the total volume needed by each product could have easily been transferred by the amount of water needed for the dice to fill up as to measure the exact volume required and the proportion or ratio of raw materials needed for each unit. The volumetric measurer will ensure that no waste of raw materials take place as it will accurately identify exactly hw much in volume of raw materials we need for a certain product to manufacture and not only that, this machine would also identify exactly how much quantity of each raw materials to use for our mixture.

Fluid mixer: the next step is to mix the raw materials. Since the grinding machine would have already taken care of the extra solid particles, we can have no worries to use the fluid mixture to mix the raw materials with hydrogen-per¬oxide.

Grease Sprayer machine: just like the paint sprayer machine is viable to be of great value to increase efficiency and quality, the grease sprayer machine would also be of state of the art equipment when the final touch of finishing after painting is required to take off pitch particles (road particles). This we offer as a different service and would be considered to have extra pricing for its use. For the manufacture of only a total package of product that we would be offering such facilities and use this machine.

Hydraulic Haul/ lift: despite being the most expensive machine in our machine and equipment lineup, this machine is essential for all purposes and aids us with all sorts of fitting arrangements with the finishing department. This would raise the vehicle as desired by our engineers to work on and have the ease of turning the vehicle 360 degrees in midair to check all joints and safety junctions after the entire service is completed. This is a good way of ensuring quality and safety for any modifications that we have done and also create confidence in our guarantee that we would provide to our customers.

5.6     Product and Service Design: The main focus and service design is customer satisfaction. Hence it is essential for our designers to understand what the customer wants and design with that in mind. Marketing is the primary source for this information. Secondary focus in product and service design relate to cost.
- Potential profit
- Quality
- Appearance
- Forecasted volume of raw materials
- Ease of production
- Ease of assembly
- Ease of maintenance and service

It would be crucial for our designee to take in to account the operations capabilities of the organization in order to achieve designs that fit with those capabilities. Therefore we should keep in mind that we let the designers know about the capabilities before hand while we thrive for in-depth customer demand realization.

In order to be successful in our business, the departments for design, operations, and marketing must work closely together keeping each other informed and taking into account the wants and needs of the customer. In addition, legal, environmental and ethical consideration can influence the design function.

Our product and service offerings are considered to be at the incubation stage. To achieve even more profit and grab an edge while appearing at the growth stage, we would need to differentiate as much as possible in our product and as well as our services which in this case is the manual labor and design.

5.7     Phases in product design and development:

  • Idea generation- supply chain and research based
  • Feasible analysis- demand, development cost and production cost and profit potential
  • Product specifications- marketing the exact method to people
  • Process specifications- alternatives in terms of cost, availability of resources, profit potential, and quality. Collaborating between accounting and operations
  • Prototype development- dice making and testing by making a random design that falls into a category of body kit.
  • Design review
  • Market test
  • Product introduction- exhibit at a show. Namely F1 auto fair.
  • Follow-up evaluation- reaction after the show

5.7.1    Computer Aided Design (CAD):
 Using computer graphics is the latest way of product differentiation and customization. We have chosen our computer software to be 3D-MAX which is high tech software of high resolution that we can use to process designing ideas into real. The use of such high tech resolution software will give the exact picture of a model of kit right after it can be manufactured so that the customer knows what we are going to give him/her before hand. There would be no changes made in the conversion process. This way we can actually make what we say and show that we could make and make our customers trust us even more.

5.7.2    The manufacturing process:
 The idea of our manufacturing process is to generate a computer manipulated graphical data into a physical unit. This is the transfer of designer expertise in the computer to the line of production in to engineering department. This brings up the reasons for collaborating our designer personnel and engineer personnel together to work as a team and to reduce as much distorted information via blue printing and scaling as possible. Our location is set with all time convenient facilities described above for the best environment for such a lay out of assembly line. The raw materials we are going to use to make the fiber are:

- SUZI (Korean named liquid fiber)
- FIBER POWDER
- NITRIC ACID
- LIQUID HYDROGEN PEROXIDE

Here we are going to have manufacturing cells which will have all kinds of specialized people to work as they can also see others' work in the following or the precedent line. We are hoping to derive motivation into each others' work this way.

5.7.3    Description of the manufacturing process:
Step # 1: All the raw materials are taken out and treated from the air tight containers and poured in to their respective buckets.
Step # 2: All the raw materials are portioned in the volumetric measurer as per the ratio of mixture between them.
Step ## 3: All the raw materials are molded & grinded for assembly.
Step # 4: After the grinding process, next we transfer the raw materials to the mixing machine for better blending and mixing.
Step # S: After step 2 which is the process of measuring the appropriate volume of raw materials required for the entire days ~NOrk, the information is transferred to the dicing department as to how to heat and mold and create the dice itself. Then it is heated in the oven for further use.
Step 0 6: After the lead is heated then it is diced in the dicing machine according to the blue print created b the designers early on.
Step tt 7.• after the raw materials are ready and so is the dice on which the mixture will be put in and evenly order, it is done so in this step.
Step # 8: the mixture in the dice itself is then left in a special sterilized chamber for cooling off and care should be taken while maintaining this process so that the mixture is kept in a stable immobile place and position. The cooling can take place in room temperature and does not require any artificial cooler making this a rather simple job.
Step # 9: After the cooling/solidification has taken place for 2 to 3 hours depending on the size of the dice and product, it is then taken out of the dice and scrubbed and polished with appropriate utensils and tools such as the sand paper to make a good finishing of the edges and corners of the product.
Step # 10: the product is further processed with grease and oil coating to make a solid finishing and unwanted edges and sharp corners are yet again removed and rounded off to make a proper smooth edge on each corners of the product. .
Step # 11: The final product is then clipped on to the designated vehicle for which the part has been made and fitted on to it by means of screwing and repeat screwing as a safety measure. Extra finishing is made after the fitting of the body kit as to ensure the longevity of the add-on.
Step # 12: as the final process before the delivery is made, the body kit is then refurbished and polished with pudding and three coats of paint is then sprayed on it to get the desired color.

5.7.4    Research and development:
The industry that we belong to is at an initial stage and does not have existing procedures and given processes of neither manufacturing nor designing. A constant check up and evaluation of research and development would be maintained to update and enhance the core competencies of our company. The core business of our product is to identify the inefficiency in every step of the manufacturing process. This can only be done by investing in the way the operation runs. We are investing in the R&D of Emunio with an agreement that we will have the `Patent Right' over their finished product. Our R&D function can boost efficiency by designing the products that are easy to manufacture. By cutting down on the number of parts that make up a product, we will decrease the required assembly time. Thus lower cost and higher profitability will be its ultimate result.

5.7.5    Quality Assurances:
Quality Assurance (QA) procedures ensure that the quality of the products is maintained by strict compliance with international fiber specifications on raw materials and finished products. Quality Control factory is equipped with, state- of -the-art analytical and fiber maintenance quality control instruments. These include latest instruments from Japan and European sources such as the hydraulic haul or lift. In addition to raw and finished product testing, tests are carried on work-in-process materials to ensure the process and hence products are always within acceptable quality limits. Also, completely separate facilities exist for fiber testing, which checks to ensure that the products are free from undesired bending due to artificial temperature or extreme heat or coldnc:,s.  Professionally competent and qualified personnel implement for the head of the research and development standard at every stage of production to build quality in to the product by maintaining proper:

- Process and Product Control Systems
- Documentation
- Environment Monitoring
- Raw Materials In process and Finished Product Quality Control
- Verified volumetric measure to ensure no wastage