Hyundai: Hammering Out Sonatas in Alabama

HOPE HULL, AL - For many auto mechanics instructors, nice late-model trainer vehicles are hard to come by. So, when I received a letter on Hyundai stationery offering me a preproduction 2006 Sonata training vehicle, I wasted no time in signing the attached form and mailing it back to the company.

I recently picked up trainer vehicle for my school, but not before touring the plant and taking a few notes. Here is a report of what I learned.

The new Hyundai production plant in Hope Hull, AL.
(Photo: Richard McCuistian)

Hyundai has assembly plants in Korea, India, China and Turkey, as well as in the United States, and it is the seventh largest automaker in the world. Hyundai was established in 1967 and began selling cars in the United States through Hyundai Motor America in Fountainville, CA in 1986. Hyundai purchased KIA, another Korean automaker, in 1998. There are more than 800 Hyundai dealers in North America, with 650 of those in the United States.

The Montgomery plant represents a $1.1 billion investment by the automaker and was under construction from April 2002 to May 2005. The Montgomery plant presently builds from 900 to 1,100 Sonatas per day, with a stated target of 300,000 vehicles year. 

The 2007 Santa Fe SUV is in preproduction here. The engine shop runs three full shifts to supply the vehicle assembly line with enough engines to run two eight- to 10-hour shifts each day. Trucks arrive at the plant's loading dock every 60 seconds with "just-in-time" parts from satellite or overseas plants. 

The finished car bodies are cleaned and coated with zinc-phosphate, which allows the undercoat to adhere to the metal. The body is then submerged 11 times in what is called a RODIP cathode dip bath that provides corrosion resistance. During this process, the car body is rotated 360 degrees so no bubbles are trapped anywhere. 

This is the showcase chassis for the 2006 Sonata on display in the plant showroom.
(Photo: Richard McCuistian)

High-speed atomizers apply primer, environmentally friendly water-based paint, and clear coat. These are all drawn to the car body by electrostatic charging for a mirror-smooth finish. 

Paint shop team members wear special coveralls and head coverings to prevent body oils, skin cells and even perfume from spoiling the paint process. Each paint shop team member passes through a special foot-washing and air-drying station to completely remove any dust or dirt particles from their shoes. Large tour groups are not permitted in the paint shop for obvious reasons; no photos are permitted inside the plant.

Cars bodies are lowered onto the chassis assembly after the engine and transaxle are installed. The car bodies are automatically raised and lowered as they move from one workstation to the next on their conveyors; this provides ergonomic comfort for the workers, says Hyundai. 

This 3.3L engine on display in the showroom is an operating model of the engines built at the Alabama Hyundai Engine plant.
(Photo: Richard McCuistian)

Team members install the tires and wheels, but the weight of the tire is supported by machinery as the team member guides it and applies the lugs.

Robots install the windshield and spare tire, along with a lot of other parts. Robots also install the battery, and a machine closes the hood. Depending on the job, some of the bolt-twisting power tools are pneumatic and some are DC electric.

Shavings from the machining process are collected and sent to a recycler. The cooling fluid used in machining is cleaned and reused. 

Five heads and five crankshafts a day are randomly pulled and checked very closely in order to keep machining within tolerances. The Korean-built transaxles are fitted to the engines in the engine shop.

Workers in the engine shop are frequently rotated from one station to the next for a number of reasons, not the least of which is to reduce wear and tear on the workers' muscles and joints. Rotation reduces carpal tunnel syndrome and related maladies. In addition, it makes each team member more proficient and alleviates boredom.

A glimpse at Hyundai's future, perhaps?
(Photo: Richard McCuistian)

Each finished unit is run through the garage where headlights and wheels are aligned and the vehicle is started and run on a dyno and checked for leaks before leaving the plant for live testing on the 2.3 mile test track. There, the car is driven up to 70 mph to be evaluated for vibration and wind noise. At a much slower speed, bumps are negotiated for evaluation of any squeaks and rattles. Finally, each vehicle goes through a manmade water shower and evaluated for body water leaks.

The Montgomery plant is designated as a foreign trade zone, meaning that each vehicle goes through U.S. Customs as a complete unit, instead of having each separate part go through customs separately.

Hyundai is extremely friendly, and, proud of their new plant, regularly receives visitors. 

The plant is just south of Montgomery between U.S. highway 331 and I-65 at 100 Hyundai Boulevard.