Automotive Assembly Course

Lesson 1 • Assembly Plant Layout and Flow

Maps the physical flow from stamping through final inspection on a typical assembly line. Students orient themselves within the production sequence.

Lesson 2 • Vehicle Architecture and Major Systems

Covers body-in-white, powertrain, chassis, and electrical systems as integrated units. Establishes the vocabulary needed for all subsequent assembly tasks.

Lesson 3 • Assembly Terminology and Documentation

Introduces work instructions, bill of materials, and engineering drawings used daily on the line. Accurate document reading prevents assembly errors.

Lesson 1 • Pneumatic and Electric Power Tools

Introduces air-powered and electric nutrunners, impact wrenches, and drills used in high-volume assembly. Safe operation and maintenance routines are emphasized.

Lesson 2 • Fastener Types and Torque Specifications

Identifies bolts, nuts, clips, and retainers by grade and application, then links each to its torque specification. Proper torque ensures joint integrity and safety.

Lesson 3 • Fastening Sequence and Joint Quality

Teaches cross-pattern and sequential tightening strategies that distribute clamp load evenly. Students verify joint quality through visual and tactile checks.

Lesson 1 • Resistance Spot Welding Fundamentals

Explains electrode selection, weld schedules, and nugget formation in resistance spot welding. Students set parameters and evaluate weld quality visually and by peel test.

Lesson 2 • Structural Adhesive Application

Introduces two-part and heat-cure adhesives used alongside welds to increase body stiffness. Correct bead placement and cure monitoring are practised.

Lesson 3 • Body Dimensional Verification

Uses checking fixtures, gap gauges, and coordinate measurement to confirm body geometry. Dimensional accuracy at this stage prevents downstream fit issues.

Lesson 4 • Closure Panel Installation

Covers door, hood, and decklid hinge installation and adjustment to achieve specified gaps and flushness. Students set striker and latch positions for proper closure.

Lesson 1 • Paint Defect Identification

Trains students to identify runs, sags, orange peel, dirt nibs, and cratering under inspection lighting. Early defect identification reduces costly rework.

Lesson 2 • Primer, Base Coat, and Clear Coat Application

Covers spray application parameters, film thickness targets, and flash times for each paint layer. Consistent application prevents solvent pop and sag defects.

Lesson 3 • Paint Repair and Touch-Up Methods

Introduces wet sanding, polishing, and spot repair techniques approved for production use. Students match repair scope to defect severity.

Lesson 1 • Powertrain Marriage Operation

Guides students through lifting, aligning, and bolting the powertrain cradle to the body at the marriage station. Correct mount torque prevents NVH issues.

Lesson 2 • Brake System Installation

Covers caliper, rotor, and brake line installation followed by system bleeding and pressure verification. Brake integrity is a primary safety requirement.

Lesson 3 • Exhaust and Fuel System Connections

Installs exhaust manifolds, catalytic converters, and fuel lines with correct sealing and heat shield placement. Leak-free connections are verified before engine start.

Lesson 4 • Suspension and Steering Assembly

Installs control arms, struts, and steering gear to specified torque and alignment targets. Correct geometry at this stage ensures safe vehicle handling.

Lesson 1 • Electrical System Verification and Testing

Uses multimeters, oscilloscopes, and scan tools to verify circuit continuity, voltage, and communication bus integrity. Faults are traced to root cause before vehicle release.

Lesson 2 • Wiring Harness Routing and Retention

Covers harness layout drawings, clip and grommet installation, and routing paths through body cavities. Correct routing prevents chafing and electrical faults.

Lesson 3 • Electronic Control Module Programming

Introduces end-of-line module flashing, VIN writing, and variant coding using plant diagnostic tools. Correct programming ensures system compatibility.

Lesson 4 • Battery and Power Distribution Installation

Installs the main battery, fuse box, and power distribution centre with correct torque and polarity. Safe handling of high-current components is emphasised.

Lesson 1 • Headliner and Pillar Trim Installation

Guides headliner positioning, retainer clip engagement, and pillar trim snap-fit attachment. Correct installation conceals wiring and provides a quality appearance.

Lesson 2 • Instrument Panel Assembly and Installation

Covers IP subassembly sequencing, cross-car beam mounting, and HVAC duct connection. Correct IP installation prevents squeaks, rattles, and air leaks.

Lesson 3 • Windshield and Glass Installation

Applies urethane adhesive, positions glass, and verifies bond cure before vehicle movement. Correct glass installation ensures structural integrity and water sealing.

Lesson 4 • Door Panel and Trim Attachment

Installs door panels, armrests, and window regulators using correct clip forces and screw torques. Proper attachment eliminates door rattle and water intrusion.

Lesson 1 • Fluid Fill and Wheel Installation

Covers engine oil, coolant, transmission fluid, and washer fluid fill to specification, followed by wheel torque. Correct fluid levels and wheel torque are pre-drive requirements.

Lesson 2 • Road Test and Dynamic Evaluation

Performs a structured road test sequence to detect NVH, brake, steering, and powertrain anomalies under dynamic conditions. Findings are documented and routed for repair.

Lesson 3 • Final Audit and Quality Gate

Applies a structured audit scoring system to measure assembly quality against customer acceptance criteria. Audit results drive immediate corrective actions.

Lesson 4 • Vehicle Launch Readiness and Handoff

Prepares the completed vehicle for shipping, including protective wrapping, documentation, and pre-delivery inspection. Proper handoff preserves quality through the delivery chain.