mapping the pathway to world-class manufacturing

8/10/2019 Mapping the Pathway to World-Class Manufacturing

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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014

BIW Material Trends

2025 Regulations Projections

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The material mix for body and closure parts will change dramatically.

Aluminum will grow to 19% of the weight and 27% of the volume for body and closure parts.

Seven out of 10 new pickup trucks produced in North American will be aluminum-bodied.

Globally, vehicle aluminum content will approach 35 billion pounds, making the automotive

industry the most important global market for aluminum.

Improved Fuel Efficiency RequirementsForecast Body & Closure

Material Mix by Volume (NAFTA)

Source: The International Council on Clean Transportation

Source: Ducker Worldwide


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BIW Construction & Innovation Trends

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Materials Joining

Aluminum

Hybrid Materials

Magnesium

Composites

Plastic

Steel

Steel variants

High Strength

BH- Steel

CP- Steel

DP- Steel

Trip Steel Life Cycle CostsAvailability Economic Criteria

Quality Reliability

Construction Types

Monocoque Hybrid Design

Sheet / Tube Space Frame

ProcessCombination

Spot Welding

Riveting

FDS

Laser Remote

Brazing/Welding

Clinching

Bonding

ProjectionWelding

TIG

MIG/MAG

Plasma

Gluing

Friction Stir

EMP

Innovation in JoiningTechniques


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BIW Advanced Materials Joining Technologies

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Resistance Spot

Welding

Drawn Arc Stud

Welding

Flow Drill

Screwing

Self Pierce

Riveting

Clinching

Laser/Mig

Welding

Techno logies that are commo n in

steel , how ever appl icat ion in

advanced mater ials is di f ferent .

Adhesive


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BIW Aluminum Body Shop

Production Rate & Joining Mix Trends

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Source: Comau Experience

SPR

RSW

FDS

Clinch

JOINING TECHNOLOGIES

PTWA

Hemming

Stud Weld

TOX

JPH

Adhesive

Laser

Rivtac

FSW


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BIW Advanced Materials Impact on Workforce

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Greater emphasis and focus on: Systems approach to vehicle design

Characterization of material properties

Interaction of a mix of materials (aluminum

steel, steelcomposite, aluminummagnesium, etc.)

Wider variety of manufacturing processes

Use of computer-aided 3D engineering

Increased manufacturability testingExample Mixed Material

Body Breakdown


7/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014

BIW Manufacturing Strategy

Critical Drivers

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Model/Architecture Flexibility - cars, SUVs, light trucks, minivans Engineered Logistics - factory material and assembly flow

Random Build Sequence - up to 4 unique models (or batch)

Volume Flexibility - scalable production rates

Compressed Timing - program development, modular install

Diverse Materials & Joining Methods - steel, lightweight materials

Lightweight BIW Building - no truss support or equipment in pits

Global Support - any geographical region




Engineered Factory Development

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2014Complete Manufacturing Strategy

ComauFlex

Intuitive and easy to monitor & manage

Safer environment

Improved logistics / reduced traffic

Consolidation of direct labor placement

Improved maintenance accessibility

(reduced MTTR)

Reduced facility footprint & volume

Enablers

Flexible/Modular Tooling

High Speed Transfers

High Density Joining

Sequenced Part Delivery

Modular Controls

Installation Solutions

2002Modular Body Shop Concept

EnablerDevelopment




Evolution

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Flexible Tooling

Flexible Conveyance

Flexible Logistics

Flexible Manufacturing Management2014

A comprehensive, production proven, flexible manufacturing

strategy that is solution-focused as opposed to component-

driven, state of the art, and technologically evolving.



BIW Example Body Framing Line/Station


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18 Robots

90 Spot Welds

47 Second Cycle

Scalable to 6 Models



BIW Example Body Framing Line/Station


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18 Robots

90 Spot Welds

47 Second Cycle

Scalable to 6 Models



BIW Logistics Sequenced Part Delivery (SPD)

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Multiple Loading To SPD Carrier

FLOW

Conventional Line Feeding

FLOW

Multiple Conveyors

Power & Free

APC

LCA

Rack Unload

Vertical

Conventional:Assembly Sequence dictates conveyor placement, affects controls /safety zones, PLC programs &

diagnostics, cycle time, robot reach and collision zones, material line feed (traffic).

SPD VersaRoll: Product architecture independent, all parts loaded at the beginning of line. Added/deleted parts do

not affect system layout or associated PLC controls & diagnostics, reduced logistics content (equipment & labor).

Improved MTBF & MTTR: reduced part feeding and loading improves system reliability and overall shop

performance.



BIW Engineered Factory w/SPD

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Material Zone

Assembly Zone

Entire Assembly Zone

Configured from 2Basic Modules

Labor Segregated byZones and Function

Material Handling

Production

Maintenance



BIW Engineered Factory Installation

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Floor Plates BRIC Legs

Shipping Modules Installed System



BIW Advanced Materials - Insuring Success Globally

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A comprehensive advanced materials strategy that focuses on a combination

of efficient designs, principals and capabilities to join premium materials

including aluminum, AHSS, PHS, carbon fiber composites and magnesium.

Technology centers located in the USA, Italy and China are continuously

developing, testing and demonstrating leading edge processes in medium to

high volume manufacturing applications.

DETROIT SHANGHAITURIN


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BIW Advanced Materials - Insuring Success Globally

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Innovation Campus in Southfield, USA Showroom and Training

R&D Center

Laser Lab

Metrology Lab

Metallurgy Lab

Controls Lab

R&D Center in Turin, Italy

Engineering Department

Laser Lab

Joining Lab

R&D Center in Shanghai, China

Showroom

R&D Center


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BIW Advanced Materials Process Testing Example

Flow Drill Screws

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Over 500,000 FDS

applied to date

Test Cell

Uptime & Fault LogHopper System

Developed for High Volume


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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th 2014

BIW Manufacturing Future

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Automotive product designteams around the world are

investing heavily in different /

new materials to respond to

government and customerdemands for improved fuel

economy, lower emissions and

reduced overall vehicle cost.

This will drive the industry to develop new stable and cost

effective solutions incorporating a variety of joining

processes within the next generation bodyshops.

mapping the pathway to world-class manufacturing

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