Hyundai raises the bar for rivals

With demand for cheap cars rising, Hyundai's Indian plants are set to exceed capacity - a challenge for a facility that makes more than 1,000 variants of cars.

Here, Hyundai i10 bodyshells are welded together by robots. No welding at Hyundai's Plant-2 'Bodyshop' (so-called because the car body comes together here) is done by hand. A fleet of 90+ robots handles every little weld.

-Text by Kushan Mitra

The car doors are welded separately from the body, here workers use gravity assisting devices to help manipulate heavy doors.

-Text by Kushan Mitra

The paint-shop is a 'No Go' area for several reasons not least of which are the chemical pollutants in the air and the potential for outsiders to ruin the paint, but these painted body-shells are coming off the paint-shop ready to enter the Final Assembly Line (FAL).

-Text by Kushan Mitra

A worker checks the order sheet that is attached to every car as it enters the line, this order sheet has 196 parameters which specify everything that needs to be done to it.

-Text by Kushan Mitra

Workers installing the roof lining on an i10 at the FAL, notice the workers have cushions on the buttocks to make life easier for them. The doors of the i10 have also been removed both to make the workers ingress and egress easier and also prevent scratches on the doors.

-Text by Kushan Mitra

Over 5000 i10's destined for foreign shores rest in Hyundai's storage yard.

-Text by Kushan Mitra

This i10 for example is going to Nigeria.

-Text by Kushan Mitra