ANALYSIS OF THE GEAR ASSEMBLY PROCESS IN THE AUTOMOTIVE INDUSTRY: A CASE STUDY AT ONE OF THE AUTOMOTIVE COMPANIES IN INDONESIA

Assembly Process

Abstract

The process of assembling the differential is a critical stage in the vehicle power transfer system because the precision of component installation, gear gap adjustment, and material quality affect the reliability of torque transmission and operational comfort. This research aims to analyze the stages of differential assembly in the automotive industry environment, identify control points that affect the quality of the assembly results, and evaluate the conformity of parameters available in the research documents. The research uses a descriptive qualitative approach with a case study design. Data were obtained thru process observation, interviews, and documentation available in the source manuscript, and then analyzed thru process flow mapping and identification of quality control points. The research results show six main stages, namely preparation and cleaning of components, installation of the drive pinion, installation of the differential case and internal gears, installation of the ring gear, adjustment of backlash and preload, and installation of the axle shaft and filling of the differential oil. The documented backlash value is 0.15 mm and falls within the reference range of 0.10–0.20 mm used in the study. Hardness testing also showed an increase from around 22 HRC before heat treatment to 55–58 HRC after heat treatment. Function tests show that the differential mechanism can operate and differentiate wheel rotation when the vehicle turns. The findings indicate that assembly precision, backlash and preload control, component cleanliness, and material characteristic control are the main control points in ensuring the quality of the differential. This research provides practical implications for strengthening process inspections and measurement consistency on the differential assembly line.
Keywords: differential; automotive assembly; backlash; preload; heat treatment; quality control.