The process of car manufacture starts with the pressing, undertaken on our behalf by Swindon Pressings, of some 350 to 400 pressed steel body panels, and the production of a number of minor sub-assemblies.

These parts are transported by train from Swindon and delivered directly into the body assembly building. Only a limited number of parts are now delivered by road, and these are mainly from other, smaller, suppliers.

The car body now begins to take shape as the panels are welded together to create major sub-assemblies such as the floor pan, body sides and roof. These larger sub-assemblies are then brought together on the "framing line" to form a recognisable body of the car.

The car then undergoes the final welding processes. During manufacture some 4,000 to 5,000 individual spot welds, mainly undertaken by robots, are made to each and every car body.
 
The remaining skin assemblies such as the doors, boot lid and bonnet are then bolted to the body shell to complete the process. The car body is then checked, before being sent to the painting process.

The painting process is broken down into three phases:

• application of anti-corrosion;
• priming of the shell
• final painting and finishing.

The anti-corrosion operation pre-treats the metal body to prepare it for priming, and to apply an anti-corrosion protective coating. Initially, a water-based detergent is sprayed over the body to remove any dirt, oils or film that may have formed. There is then a phosphating process that applies a corrosion-resistant crystalline coating of zinc phosphate and provides improved adhesion for the paint primer.

The priming phase involves 4 coatings: an electro-deposition primer coating; a sealant; an anti-chip coating and the primer-surface coating.

The primary colour coat, called the basecoat, provides the basic colour to the car, and a top clearcoat is applied to protect the basecoat from mechanical, chemical or biological attack. This also gives the car its high gloss finish appearance.

The final assembly process completes the car.  This involves a diverse range of parts and components that are manufactured all over the world. The painted body shell enters the car assembly building [CAB] and the process begins.

Initially, the car electrical harnesses and various interior trim items are fitted. This is followed by much of the under body parts such as the exhaust system. The glazing is fitted along with the engine, steering and suspension systems and road wheels. The final interior fitting is then undertaken, e.g. the seats, steering wheel, etc.

Once completed, all the fluids are added such as brake and steering fluids and anti-freeze, and a limited amount of fuel is added into the fuel tank.

The car is ready to be started and driven onto a rolling road for a functional test. The car is then put through a water test and passed to final inspection before it is passed to dispatch.