AutomotiveSupplyChain.ppt

7/30/2019 AutomotiveSupplyChain.ppt

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Prepared by:Ankur Kumar SharmaMayank GuptaSaurabh Mishra


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Conserving energy through more efficientprocesses, technologies, and products

While many manufacturing facilities today aremodernized and relatively efficient, significantopportunities remain to reduce energy demand

via innovation and research and development(R&D)


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Body in White (BIW) refers to the stage inautomotive manufacturing in which the vehiclebody sheet metal (doors, hoods, and deck lids)has been assembled but before components

(chassis, motor) and trim (windshields, seats,upholstery, electronics, etc.) have been added.


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Joining Solid state joining methods for similar and

dissimilar materials (ultrasonic, magnetic,pulse)

Non-heat cured adhesives (induction)

Better software to predict formability, springback, joining, and processing parameters


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New hybrid joining methods and mixingtechnology (welding and adhesives, mixprocesses, fasteners and adhesives, laserassisted arc welding)

Efficient Part Forming and ShapeHydro-forming (tubular and sheet); lower

energy through reduced mass and wastematerial


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Materials Development for In Process Use Composites made from non-petroleum

based raw materials

Low-cost carbon fibre and manufacturingmethods for low-mass stronger plastics


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BIW Systems Miniaturized, lightweight tools: welders,

riveters, etc. that lead to smaller, lighter,

lower power robots that work faster and moreefficiently

BIW Design Tubular structures: new designs, connections,

tubes made from advanced high strength

steel (AHSS)


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In the automotive paint shop, the bodystructure from BIW undergoes a series ofoperations to paint both the interior andexterior of the structure

Before 1985-single-stage paint

Now-multistage- 5 layer

1)application of pretreatment and electrocoat

2) primer layer 3) basecoat and clearcoat


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produces a lustrous finish but process is bothcostly and time-consuming

take 3 hours per vehicle to complete and usesconsiderable amounts of materials, electricity,natural gas, and labour or robotics

Compact paint systems, for example,eliminate either the need for a separate

primer layer altogether or reduce processcomplexity while retaining the benefitsprovided by the primer layer


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Propulsion and Chassis Systems While improvements will continue to be made to

internal combustion engine (ICE) systems, futureproducts will include a mix of propulsion

technologies, like using aluminium basedengine.

One size powertrain for all vehicles couldemerge, with a reduction in parts and processing.

Next generation powertrain systems will use

lighter weight materials and processing andfewer joints using a combination of carbon fiber

Robust technologies for hybrid batteries will beavailable; high volumes of batteries will berequired to supply hybrid and plug-in vehicles.


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A transmission control unit or TCU is a devicethat controls modern electronic automatictransmissions.

A TCU generally uses sensors from the vehicle as

well as data provided by the Engine Control Unitto calculate how and when to change gears in thevehicle for optimum performance, fuel economyand shift quality.

It uses various sensors like Vehicle speed sensor(VSS), Throttle position sensor (TPS), TractionControl System .


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Thus using this TCU would save fuel with tractioncontrol.

ECU is employed in new cars which decides a lots

of features in car and maintain fuel efficiency.

TCU and cruise control are part of it.

One of the important part of this configuration isCVT( continuous variable transmission) thisoffers a number of gear ratio which provideincreased efficiency


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Heat TreatingLocalized heat treatment design/transient processing(in situ) that eliminates the furnace; possibilitiesinclude non-bulk heat-treating processes (laser,microwave, magnetic field, induction, etc.)

-Real-time capability to apply energy where it isneeded, when it is needed

-Achieve high strength in particular areas of a partwithout using energy on waste material

-Surface-only heat treating (combine heattreatment with casting)

-Heat-treat in the foundry -Well-controlled cooling


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Energy Assessment Energy mapping multi-use energy database for

processes for designers, managers, others, toidentify sub-energy use for processes (metalremoval, machining, HVAC and oil mist andventilation, coolant filters, metal melting)

-Quantify where energy is used andsource/function (electrical, air, motion, hydraulic)

-Enable prioritization of energy reductionopportunities for powertrain and chassis based on

annual use, opportunity to improve, and ease ofimplementation


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Assembly Processes and Parts/Component Supply Energy in material handling and movement is minimized through

use of lighter weight materials, efficient conveyor design,wireless tracking and other technologies

Energy efficient tools and processes minimize or eliminate

compressed air, reduce hydraulic energy, and permeate DCtools and robots

Designs incorporate flexible, re-configurable work stations tohelp reduce waste in model change-overs and create moreefficient floor space design to minimize movement of materials

Energy is optimized, from raw materials to suppliers and finalassembly: energy is reduced in supply chain

Final assembly shifts to dealerships


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AutomotiveSupplyChain.ppt

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