Post on 02-Jun-2018
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
8/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
BIW Manufacturing Strategy
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
9/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
BIW Manufacturing Strategy
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.
8/10/2019 Mapping the Pathway to World-Class Manufacturing
10/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
BIW Example Body Framing Line/Station
High Density Joining
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18 Robots
90 Spot Welds
47 Second Cycle
Scalable to 6 Models
8/10/2019 Mapping the Pathway to World-Class Manufacturing
11/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
BIW Example Body Framing Line/Station
High Density Joining
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18 Robots
90 Spot Welds
47 Second Cycle
Scalable to 6 Models
8/10/2019 Mapping the Pathway to World-Class Manufacturing
12/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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.
8/10/2019 Mapping the Pathway to World-Class Manufacturing
13/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
14/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
BIW Engineered Factory Installation
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Floor Plates BRIC Legs
Shipping Modules Installed System
8/10/2019 Mapping the Pathway to World-Class Manufacturing
15/182014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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2014 CAR Management Briefing Seminars Comau PresentationAugust 4th, 2014
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
8/10/2019 Mapping the Pathway to World-Class Manufacturing
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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.