Características de los instrumentos de recogida de datos

Often the car driver faces the problem, the headlight beam adjustment. Because of the maladjustment the light beam falls on unwanted objects. At the headlamp tester, a yellow cross represents the position of the headlamp whereas the point where it should ideally be is shown as green rectangle. The operator manning the test tries to get the yellow cross inside the green rectangle by adjusting screws for horizontal and vertical alignment of the lamp.

Apart from checking the headlamp, turning radius and other things are also checked at this checkpoint.

Appearance Test

This test involves evaluating a vehicle on a large number of parameters ranging mainly from external appearance of the vehicle to the internal trim fittings to checking for coolant level and braking fluid level. The vehicle is loaded on a conveyor. The vehicle is visually inspected for weld, paint and assembly defects and the same are marked on the diagrammatic representation given on the checksheet. The appearance check points are I.D plate, emblems, bumper, doors, fuel lid, front hood, routing and clamping, seats, interiors, seat belts, weather strips, tyres and glasses.

Various paint defects are paint peel off, scratches, paint miss, overflow, orange peel, shade mismatch, pin holes sealer application and sanding marks. Various weld defects are level difference, dents, door gap and fouling.

The vehicle is driven in all the gears and the various parameters checked are as follows: GITM GURGAON

 Steering wheel : position/vibration

 Clutch : free play 20-30 mm/noise/engagement/disengagement  Accelerator Pedal: free play 2-7 mm/operation

 Gear shifting: hard/noise/slippage

 Speedometer: needle vibration/error/reading at 40 km/h  Horn: volume/tone

 Wiper/washer (front/rear): auto stop position/wiping/spraying position

 Warning lamps and indications: parking brake/battery changing/oil pressure/hazard lamp/turn signal/pilot lamp/room lamp/panel light/pre heat/brake oil indication.

 Rear view mirror: blurred image/ distortion  Fuel/Temperature gauge: function

 Lamps: Parking, head lamp high/low, side turn signal, cabin lamp/door switch/fog lamp, brake light, hazard lamp, reverse light

 Blower: Operation of switch at different speeds, air direction control, fresh/re- circulating air control, fins

 Heater: functioning, switch operation  A/C: functioning, switch operation  Choke: operation/ function

 Abnormal noise of any kind from wheels/body/engine should not be there.

Brake Tester

The front and rear brake forces are measured here. Here the brake pedal is checked for hardness, sponginess, play and noise. Parking brake force is also checked here. The vehicle is moved onto the drums, vehicle brakes are employed and the corresponding resistance force is measured with the help of computerized machine. The measured force is displayed on the screen and must lie between the values prescribed by the company.

Engine Room

Here the engine is inspected for various kinds of defects such as tappet noise, clutch lever play (Car800), exhaust emissions as per the standards laid down, idling rpm with and without A/C switched on. In case of MPI cars, a DLC (Data Link Connector) cable is used to detect the working of Electronic Control Module and various sensors. The DLC cable is connected to a computer which shows not ok if there is any malfunctioning in the engine. The defects are noted on the checksheet to be repaired in assembly or engine assembly.

Pit Inspection

The underbody of the vehicle is checked for: Brake fluid/coolant/fuel/engine oil leakage

Red and yellow paint on nuts, bolts and fuel and brake pipes (the paint indicates that the nuts and bolts have been properly assembled and checked for torque)Muffler mounting bolt Rear suspension coil or leaf spring

Shower Tester

The vehicle is moved on the shower tester conveyor belt where it passes through a series of shower jets aligned at different angles and locations. While passing through, the vehicle is sealed i.e. all window glasses are rolled up and doors closed. When the vehicle exits from other side of the shower tester an inspector checks the cabin for water seepage. If water is found, then the particular leak defect is repaired in the shower repair section following which the vehicle is sent for the road test.

Road Test

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Road test of a vehicle consists of a track on which the vehicle is run at predetermined speed. The track is designed so as to check the various aspects of the vehicle such as braking, acceleration, handling, performance etc. Distance traveled after application of brakes, reverse braking and Steering positioning is also checked. After driving the car at a fast speed it is made to take a U-turn to try and find for any loose part in the panel. Other parameters checked in the road test are:

 Steering stability: position/play/vibration  Clutch/accelerator pedal: play/noise  Brake: noise/sponginess/brake pulling  Rear view mirror: blurred image/distortion

 Gear shifting: gear slip/engagement/hard disengagement/noise  Defogger: functioning

 Speedometer: needle vibration

 Abnormal noise of any kind from panels, doors, wheels , engine, hood etc is noted down

Final Check

This is the last of the vehicle inspection checks. After the vehicle has gone through the other tests and if there are no repairs to be done then it is sent to final check. Here the overall appearance of the vehicle is checked again.

Scratches, dents, cleanliness and Cemedine(windscreen sealer) leftovers are checked for. Also secondary defects i.e. defects that may creep in while repairing the primary defects are also checked for. Inspection stamps for all the previous check stations are checked to see that there is no inspection miss. Finally the chassis and engine number on the I.D. plate are verified and the Final Check OK ( FCOK) sticker is put on the car and it is sent to the final check parking area. FC OK’ed vehicles are later picked by the Sales and Dispatch drivers.