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Page 1: IAC PowerPoint Templatecargroup.org/wp-content/uploads/2017/08/Ryntz.pdf · French Seam 8mm French Seam 6mm French Seam 8mm French Seam 8mm Oven Adhesive Spray Booth Heat Seal Seam

Automotive Manufacturing

July 31, 2017

Highly Crafted Interiors

Rose A. Ryntz, Ph.D.

VP Advanced Development and Material Engineering

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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

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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

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IAC Group – Proprietary and Confidential 4

Craftsmanship

Toyota 1997

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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)

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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

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IAC Group – Proprietary and Confidential 7

Craftsmanship

Glass – 2017 Lexus LS 500

Use of Exotic Materials, Sewn Components, and Integrated Electronics

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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

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IAC Group – Proprietary and Confidential 9

Concept to Production

Concept Design & Validation Production

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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

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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

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IAC Group – Proprietary and Confidential 12

Effect of Adding a Live Stitch

Mechanical

Skive

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IAC Group – Proprietary and Confidential 13

Craftsmanship

Pattern Development and Stitching

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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

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IAC Group – Proprietary and Confidential 15

Craftsmanship

Laminating and Edge Wrapping

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

adhesive selection

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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

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IAC Group – Proprietary and Confidential 17

Cut & Sew Global Technology Centers

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IAC Group – Proprietary and Confidential 18

Cut & Sew Global Production

IAC Regional Support

Manufacturing Facility

Design, Technical, Commercial Center

IAC Group JV

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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

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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

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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

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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

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IAC Group – Proprietary and Confidential 23

Cut & Sew Manufacturing Locations

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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

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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

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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

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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

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IAC Group – Proprietary and Confidential 28

Flaming line Wrapping and Press Lamination

Spray Line Wrapping Part Storage

IAC China Hangzhou Plant

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IAC Group – Proprietary and Confidential 29

Cut & Sew Advanced Technology

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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)

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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?

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IAC Group – Proprietary and Confidential 32

Cut and Sew Development Core Competencies

Vertically Integrated Process

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IAC Group – Proprietary and Confidential 33