Light weight parts and chemical management in auto industry

Transcription

1 Light weight parts and chemical management in auto industry Satoshi Asada MOTOR CORPORATION 1

2 1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals 2

3 JAMA member companies 14 companies (Passenger, Truck & Bus, Motorcycle ) 3

4 JAMA Committee Organization Board of Directors Executive Committee Environment Committee Factory Environment S/C Chemical Substance Management S/C Regulatory trend monitoring Vehicle Indoor Air Quality Collaborate oversea w/auto sector (GADSL, AI-REACH TF etc.) Windows to other industries Windows to the JPN Government Environment Issues S/C Recycling & Waste Reduction S/C 4

5 1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals 5

6 Environmental Challenge Challenges 6

7 Environmental Challenge New vehicle zero CO2 emissions challenge ~ 90% by 2050 compared to 2010~ Engine powered Vehicle HV PHV FCV EV

8 Environmental Challenge Life Cycle Zero CO2 8

9 1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals 9

10 CO2 trend for vehicle 50% Reduction 1 Power train efficiency 2 Vehicle aero performance 3 Weight reduction Taiwan Brazil Saudi Arabia Australia Mexico China 75 Korea EU 67 10

11 Material composition trends 1968 (1020kg) 1978 (1144kg) Mark II 1988 (1300kg) 1996 (1313kg) 2000 (1371kg) Lexus IS 2011 (1471kg) Steel Rubber Nonferrous metal Glass Plastics Others 11

12 Slim up!! philosophy 1. Steel weight reduction as much as possible Even now, Steel is the major component in automobile So, Weight reduction for Steel is the main measure. -> Use High-tensile steel as much as possible -> Precis control Steel plate thickness as parts shape -> Partial optimization for Material Strength -> Optimizing Material joining methods 2.Utilizing Light weight materials Aluminum(Hood Cover, Chases part, Body part etc.) Magnesium(Similar application for Aluminum) Plastics(External panel etc.;recycle, Flame retardant etc.) 12

13 Light weight material trend SUPRA HOOD 01 SC430 HOOD, ROOF BACK WINDOW FRAME 94 CELICA GT4 HOOD 94 RAV4 ROOF 06 LS600h/460 HOOD 09 SAI HOOD 11 CT HOOD LIFTGATE 11 Prius α HOOD 15 MIRAI Stack flame Brake Pedal BRKT Steering Column Jacket 10 LFA Cabin Steering Wheel Core Seat Frame Air Bag Housing Engine Head Cover Cost, Performance, Mass Productivity, & Necessity 13

14 Adoption trend C-FRP parts CFRP Roof CFRP Side-door Luggage Roof CFRP Spoiler CFRP Rear wing CFRP Roof CFRP hood Thermoplastic CFRP FC stack flame FC hydrogen FCタンク tank CFRP Backdoor CFRP hood Core technology was developed In Lexus LFA & spreading Application. 14

15 Fuel Cell vehicle MIRAI C-FRP parts FC stack flame Hydrogen tank Significant weight reduction modify the structure Thermoplastic CFRP sheet Worldwide first auto application Thermoplastic CFRP part MIRAI 15

16 C-FRP Hydrogen tank Dome section Boundary section Cylindrical section Specification Pressure 70 MPa Volume L(60.0 L+62.4 L) H2 storage 5.0 kg Base Plastic Liner (Seals in H2) CF reinforced plastics (Pressure resistance) GF reinforced plastics (Surface protection) Boundary section Dome section Cylindrical section Liner CF-Prepreg Helical winding High angle Helical winding Hoop winding 16

17 Prius-PHV back-door C-FRP (C-SMC) TSOP -Weight reduction 40% weight reduction compared with Aluminum -Design flexibility Double bubble shape (aerodynamic) Better visibility 38.3 for Prius 40 for Prius-PHV 17

18 Lexus LC500 coupe V-8 5.0L 477PS 2WD(FR) Vehicle weight:1.940kg 18

19 Lexus LC500 C-FRP parts CFRP Roof CFRP Luggage inner CFRP Door inner 19

20 1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals 20

21 Complexity & parts number Complexity parts structure & Number!! Assembly pats : 2,000 3,000 / vehicle Body : 1 Engine : 1 Transmission : 1 Component parts: 50,000 and more / vehicle Engine component Body component Transmission component 21

22 Automotive supply structure Auto-OEM (JAMA, ACEA, USA) One Auto-OEM Have 3,000 Tier1 suppliers Part suppliers (JAPIA, CLEPA etc.) Auto OEM Tier1 Tier1 Tier2 Tier2 Tier2 Tier3 Tier3 Tier3 Tier3 TierN TierN TierN TierN TierN Metal (Steel, Nonferrous) Chemical (Plastics, Paint Adhesive, Fluid Rubber etc.) Electric & Inorganic materials 22

23 Complexity of auto supply chain (Overseas, law material / article ) Domestic supplier Oversea supplier Tier 1 (1,500) Tier 2 (750,000) Tier 3 Tier N 23

24 Green Purchasing Guideline _Green_Purchasing_Guidelines_2016_en.pdf 24

25 IMDS/GADSL collaborations IMDS : International Material Data System Material data (not only materials info.) -Parts info. -Supplier info. -Base material info. -Hazardous substance info. Data collection system Data format & archive & rule GADSL: Global Automotive Declaration Substance List Substance list 25

26 Outline of IMDS What is IMDS? A common platform for collecting/analysing components/material information in the automotive industry. An environmental information communication system that 8 European OEMs (Audi, BMW, Daimler Chrysler, Ford, Opel, Porsche, Volkswagen, Volvo) have led development. Operated by major OEMs in Asia/US/EU with cost contribution. (6,000,000 euro/year) A system accessible through an internet. Suppliers can use the system free of charge. The system will be available immediately after online registration. Almost de facto standard in automotive industry for data collection. 26

27 IMDS data flow Structure of IMDS OEM Tier1 Tier2 Material maker MDS request for assy MDS request for component MDS request for material MDS data for assy MDS data for component MDS data for material IMDS data center (former HP) 27

28 IMDS adopting auto-oem Auto OEM Membership trend Participating OEMs : over 30 Participating Suppliers: 168,626 Registered users: 464,725 people (as of April 2018)

29 Current status IMDS data Approximately 168,626 companies, 69,644,0079data (as of Apr. 2018) IMDS registered companies 100,000 IMDS registered companies and data amount IMDS registered data amount 35,000,000 90,000 IMDS registered companies IMDS 登録企業数 IMDS registered data IMDS amount 登録データ数 30,000,000 80,000 70,000 25,000,000 60,000 20,000,000 50,000 40,000 15,000,000 30,000 10,000,000 20,000 10,000 5,000,

30 IMDS/GADSL collaborations IMDS : International Material Data System Material data (not only materials info.) -Parts info. -Supplier info. -Base material info. -Hazardous substance info. Data collection system Data format & archive & rule GADSL: Global Automotive Declaration Substance List Substance list 30

31 Outline of GADSL Global Automotive Declarable Substance List <Remark> First GADSL is issued in 2005 and revised every year GADSL issued Feb. 1 st 2018 The official GADSL will be the current English version as posted on the GADSL website: 31

32 GADSL pre-view Classification P: Prohibited D: Declarable Reason code LR: Legally Regulated FA: For Assessment FI: For Information 229: Substance Group 3284: Substances Source EU: REACH, Member states law etc. USA: TSCA, State law CANADA: CPCYS, CANADA Challenge Japan: Chemical Substance Control Law UN: POPs, Monitorial treaty 32

33 GASG collaborations Global Automotive Stakeholder Group GASG Steering Committee Members of automotive, supplier, chemical industries Coordination Team Auto OEM Suppliers ACC (American Chemistry Council) Auto OEM JAPIA JCIA (Japan Chemical Industry Association) Auto OEM CLEPA (European Association of Automotive Suppliers) Cefic (European Chemical Industry Council) GADSL is managed by the Global Automotive Stakeholder Group. GASG is a voluntary organization of the Automotive Supply Chain. 33

34 1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals 34

35 Expectations to the Chemical Industry - Close communication for the chemical regulation + Regulatory trend + Handling of regulated substances & alternatives ( Auto industry needs to allow a significant lead-time for the evaluation & to commit to supply legacy spare parts) - Collaborate with supply chain for the information exchange + Detail substance information + Detail mixture information + Equivalent criteria for Classification - Maintain the hot line among Chemical & Auto industry 35

36 Thank you for your attention 36