IAC PowerPoint Templatecargroup.org/wp-content/uploads/2017/08/Ryntz.pdf · French Seam 8mm French...

of 33 /33
Automotive Manufacturing July 31, 2017 Highly Crafted Interiors Rose A. Ryntz, Ph.D. VP Advanced Development and Material Engineering

Embed Size (px)

Transcript of IAC PowerPoint Templatecargroup.org/wp-content/uploads/2017/08/Ryntz.pdf · French Seam 8mm French...

  • Automotive Manufacturing

    July 31, 2017

    Highly Crafted Interiors

    Rose A. Ryntz, Ph.D.

    VP Advanced Development and Material Engineering

  • IAC Group – Proprietary and Confidential 2

    Agenda

    Growth of Crafted Interiors

    Feature Trends

    Global Development Centers

    Required Core Competencies

    Global Manufacturing Capability

    Innovative Advanced Projects

    Global Know-How and Technology

  • IAC Group – Proprietary and Confidential 3

    Advanced Technology

    Interior Market - Feature Trends 1997

    Woodgrain

    Cell Phone Holder

    Storage

    Radio with

    Casette Player

    Soft Arm Rests

  • IAC Group – Proprietary and Confidential 4

    Craftsmanship

    Toyota 1997

  • IAC Group – Proprietary and Confidential 5

    Industry Update 2017

    JD Power Consumer Quality Survey

    1) Reliability/Durability

    2) Interior

    Finding a vehicle interior to be

    comfortable and of high quality is the

    second most frequently cited reason for

    buying a new vehicle.

    3) Exterior Styling

    4) Gas Mileage

    5) Quality of Workmanship

    6) Dealer was Convenient/Liked Dealer in Area

    7) Performance

    8) Advanced Technology

    9) Like the Image Vehicle Portrays

    10) Safety

    16% of poor quality issues cited by

    consumers were related to interior:

    Materials scratch/scuff easily

    Excessive wind noise

    Odor/VOC (China)

  • IAC Group – Proprietary and Confidential 6

    Advanced Technology

    Interior Market – Feature Trends 2017

    Leather Cut &

    Sew

    Components Multi-color

    Multi-texture

    Mass Reduction

    Patterned Metallic

    Decorative

    Accent Stitching

    Multiple

    Information

    Displays

    Doubled Up Stitch Patterns

    Exterior to Interior Cues

    Surface Decorations

    Connectivity

    Storage

    Safety

    Environmental

    Decorative Lighting

    Durable Materials

  • IAC Group – Proprietary and Confidential 7

    Craftsmanship

    Glass – 2017 Lexus LS 500

    Use of Exotic Materials, Sewn Components, and Integrated Electronics

  • IAC Group – Proprietary and Confidential 8

    IAC Global Cut & Sew CapabilityTo

    da

    y2007

    Pattern Development Part Production Product Lines Manufacturing

    Locations

    INDUSTRY SHIFT• OEM’s desire for brand differentiation

    • Consumer demand, luxurious appearance

    • Consumer demand, soft touch interior

    2

    Vehicle

    Platforms

    3

    Parts

    33 100+

    DOOR

    Armrest, Upper, Bolster

    CENTER CONSOLES

    Armrests, Side Panels

    INSTRUMENT PANELS

    Seamless Uppers, Binnacles,

    Lowers, Glove-box Outers,

    Seatbacks, Headliners, Visors

    Armrests , Bolsters

    Toluca, MX

    Saltillo, MX

    Arteaga, MX

    Ramos, MX

    Hermosillo, MX

    Iowa City, US

    Warren, US

    Coleshill, UK

    Plattling, Germany

    Hodonin, Czech

    Lozorno, Slovakia

    Hangzhou, China

    Opoloe, Poland

    Saltillo, MX100% Outsourced

    100% Vertical Integration

    Troy Trim Lab

    Hangzhou Trim Lab

    Coleshill Trim Lab

    Ebersberg Trim Lab

    CAPABILITY

  • IAC Group – Proprietary and Confidential 9

    Concept to Production

    Concept Design & Validation Production

  • IAC Group – Proprietary and Confidential 10

    Prototype Development

    Build Support

    Rapid prototype capabilities:

    FDM (fuse deposition modeling) – extrudes layers of ABS

    SLA (stereo lithography) – laser beam cures photochemically

    reactive resin; mimics nylon

    SLS (selective laser sintering) – uses laser beam to build a part;

    mimics PP

    Part fabrication & mock ups

    Process development/optimization

  • IAC Group – Proprietary and Confidential 11

    Craftsmanship

    Effect of Stitch Type on Application

    Stitch and material join can affect how part surface appears after decoration

    Join sew “selvage” can change design of part

    Foam in Place (FIP) Sealing ProcessSlush Skin Sewing Sealing Tape Foam in Place

  • IAC Group – Proprietary and Confidential 12

    Effect of Adding a Live Stitch

    Mechanical

    Skive

  • IAC Group – Proprietary and Confidential 13

    Craftsmanship

    Pattern Development and Stitching

  • IAC Group – Proprietary and Confidential 14

    NC Cut File

    RH Topper + 3 Inner Binnacles + 2

    Outer Binnacle Facings 1 Yd 0.2”

    Steel Rule Die

    RH Topper + 1 Inner Binnacle + 2

    Outer Binnacle Facings 1 Yd 3.0”

    Coverstock Pattern Nesting

    Optimizing Material Usage

  • IAC Group – Proprietary and Confidential 15

    Craftsmanship

    Laminating and Edge Wrapping

    Very manual process, seam alignment very labor intensive and dependent upon

    adhesive selection

  • IAC Group – Proprietary and Confidential 16

    Auto Edge Wrap- Servo

    driven (x4)

    Shuttle Heater-

    interchangeable heater pack

    Edge wrap heaters- IR (x2)

    and hot air (x2)

    Lamination/Edge Fold

    Manufacturing Tools

    Vision system for

    alignment check of seam

  • IAC Group – Proprietary and Confidential 17

    Cut & Sew Global Technology Centers

  • IAC Group – Proprietary and Confidential 18

    Cut & Sew Global Production

    IAC Regional Support

    Manufacturing Facility

    Design, Technical, Commercial Center

    IAC Group JV

  • IAC Group – Proprietary and Confidential 19

    Central European Cut & Sew Lab

    Ebersberg, Germany

    Leather

    Splitter

    Edge Skive

    Salvage Trim

    Join

    French Seam

    8mm

    French Seam

    6mm

    French Seam

    8mm

    French Seam

    8mm

    Oven

    Adhesive

    Spray Booth

    Heat Seal

    Seam Tape

    Punch

    Machine

  • IAC Group – Proprietary and Confidential 20

    Northern European Cut & Sew Lab

    Coleshill, United Kingdom

    Small Press

    Lamination

    Seam alignment

    Fixture

    Twin needle machine Single needle Machine

    Pattern development

    and digitising

    CNC leather hide cutting

  • IAC Group – Proprietary and Confidential 21

    North America Cut & Sew Lab

    Troy, MI, USA

    Digitizing

    Station

    Leather

    Splitter

    Gerber

    CutterSalvage Trim

    JoinFrench Seam

    6mm, 8mm, 10mmDeck Seam

    2D Automatic

    Edge SkiveHeat Seal

    Seam Tape

    Adhesive Roll

    Coat

    Press

    Lamination

  • IAC Group – Proprietary and Confidential 22

    China Cut & Sew Lab

    Hangzhou, China

    French Seam

    6mm, 8mm, 10mm

    2D Automatic Deck SeamAirbag sewing

    machineFunction Seam CNC leather hide cutting

  • IAC Group – Proprietary and Confidential 23

    Cut & Sew Manufacturing Locations

  • IAC Group – Proprietary and Confidential 24

    IAC Group Asia

    Highlighting Cut & Sew Facilities

    Beijing (Songjiang-JV)

    Beijing

    Changshu

    Changshu (Songjiang-JV)

    Chongqing

    Hangzhou

    Shanghai Engineering Center

    Shanghai (Songjiang-JV)

    Shanghai

    Shenyang (Songjiang-JV)

    Tianjin (Songjiang-JV)

    Wuhan (Xiang Xing-JV)

    Wuhan (Songjiang-JV)

    Yantai

    China

    Chakan I, Pune

    Chakan II, Pune

    Manesar I, Haryana

    Manesar II, Haryana

    Pune

    Thane

    India

    Yokohama

    Japan

    Seoul

    Rayong

    Thailand

    Korea

    Manufacturing Facility

    Design, Technical, Commercial Center

    IAC Group JV

    http://www.dreamstime.com/national-flag-of-china-image5397018http://www.dreamstime.com/national-flag-of-china-image5397018http://www.dreamstime.com/japan-flag-image5404727http://www.dreamstime.com/japan-flag-image5404727http://www.dreamstime.com/button-image3188086http://www.dreamstime.com/button-image3188086

  • IAC Group – Proprietary and Confidential 25

    IAC Group North America

    Highlighting Cut & Sew Facilities

    Albemarle, NC

    Alma, MI

    Anniston, AL

    Dayton, TN

    Fremont, OH

    Greencastle, IN

    Holmesville, OH

    Huron, OH

    United States

    Maple

    CanadaArteaga

    Hermosillo

    Monterrey

    Puebla

    Mexico

    Manufacturing Facility

    Iowa City, IA

    Madisonville, KY

    Mendon, MI

    Montgomery, NC

    Old Fort, NC

    Port Huron, MI

    San Antonio, TX

    Sidney, OH

    Spartanburg, SC

    Springfield, TN

    St. Clair, MI

    Strasburg, VA

    Warren, MI

    Wauseon, OH

    Queretaro

    Ramos

    Saltillo

    Toluca

    http://www.dreamstime.com/button-image3258230http://www.dreamstime.com/button-image3258230http://www.dreamstime.com/button-image3149801http://www.dreamstime.com/button-image3149801http://www.dreamstime.com/button-image3228772http://www.dreamstime.com/button-image3228772

  • IAC Group – Proprietary and Confidential 26

    IAC Group Europe

    Highlighting Cut & Sew Facilities

    United Kingdom

    Coleshill

    Elmdon

    Halewood

    Scunthorpe

    Sunderland

    Germany

    Bad Friedrichshall

    Celle

    Hamburg

    Lambrecht

    Plattling

    Straubing

    Zwiesel

    Romania

    Bals

    Spain

    Logroño

    Vitoria

    Poland PoznanOpole

    Netherlands

    Born

    Belgium

    Grobbendonk

    Sweden

    Färgelanda

    Låssby

    Skara

    Carpets & Acoustics

    Plastics

    Czech Republic

    Hodonín

    Přeštice

    Zákupy

    Slovakia

    Lozorno

  • IAC Group – Proprietary and Confidential 27

    Mexico Cut & Sew Manufacturing

    Gerber Cutter

    Salvage Trim

    JoinFrench Seam

    6mm, 8mm, 10mmDeck Seam2D Automatic

    SewingEdge Skive

    Heat Seal

    Seam Tape

    Press

    Lamination

    Bladder

    Lamination

    Manufacturing locations utilize same equipment as utilized in development

  • IAC Group – Proprietary and Confidential 28

    Flaming line Wrapping and Press Lamination

    Spray Line Wrapping Part Storage

    IAC China Hangzhou Plant

  • IAC Group – Proprietary and Confidential 29

    Cut & Sew Advanced Technology

  • IAC Group – Proprietary and Confidential 30

    Cut & Sew Development

    Global Advanced Projects

    New Cut & Sew materials

    e.g. wood veener with fleece backing and laser perforation

    2 D sewing pattern / 3D Robot sewing active

    surface materials

    e.g. laser perforation decor with backlit

    heated surfaces

    High crafted combination of materials

    e.g. use of fabrics/mesh/foam

    e.g. Stitching of Skins

    Seamless airbag opening on Cut & Sew

    materials

    e.g. PU Foil, Alcantara, Leather by weakening with ultra

    short pulse laser (Femto)

  • IAC Group – Proprietary and Confidential 31

    5 Global Cut & Sew Tech Centers

    IAC Troy NA

    IAC Ebersberg EUPremium Products

    Volvo V/S 90 EUNissan Maxima NAAudi Q7 EU

    Expertise in all types of sewing styles inc. stitching &

    design support

    Global pattern development (cut, scan, documentation)

    Global cut & sew decor material know-how

    (leather, PVC, PU foil, fabric, Alcantara)

    Expertise with all types of constructions

    (foam, spacer textile, rolled foam)

    Global laminating know-how (process, glue)

    IAC Core Technologies Summary

    Cut & Sew Crafted Surfaces

    What is Required?

  • IAC Group – Proprietary and Confidential 32

    Cut and Sew Development Core Competencies

    Vertically Integrated Process

  • IAC Group – Proprietary and Confidential 33