Alan D. Whitted. Global Head of Press Shops & Dies - FCA

Transcription

1 Alan D. Whitted Global Head of Press Shops & Dies - FCA

2 AGENDA Introduction Technology Talent Summary

3 U.S. TOOL & DIE INDUSTRY 1998 Mfg: 412.5K Tool: 9.1K 2008 Mfg: 359.5K Tool: 6.4K 2014 to 2024 Tool & Die Maker employment projected to decline 13% due to foreign competition and automation advances Mfg: 365.4K Tool: 7.2K 2010 Mfg: 342.8K Tool: 5.8K 36% drop in the number of U.S. tool and die shops between 1998 and 2010 As a result, employment in tool and die has dropped rigorously and is projected to further decline Skill sets required to change for workforces as automated tooling increases The innovation of technology and fluctuation of new model programs has required tool and die shops to operate differently Sources: 1. Canis, B. (2012). The Tool and Die Industry: Contribution to U.S. Manufacturing and Federal Policy Considerations. Retrieved from the NTMA website: 2. U.S. Bureau of Labor Statistics (BLS), Employment Projection Program 3.

4 DIE SHOP CAPACITY & LOAD Die Shop Load (3 Year) Year 1 Year 2 Year Load (Hours) Capacity (40 Hours) Load Trend Issues with financial lulls: Manpower loss (skill sets) Investment difficulties Struggle to stay afloat

5 DIE SHOPS DIVERSIFY TO SURVIVE Different Business Models Press Production Sub-Assembly Build Diversify Customer Adding production Construction of Military (ITAR) base volume capacity sub-assemblies Separate businesses Production run of Production run of within Tool & Die service parts service parts Shops o Engineering o Machining o Construction o Tryout

6 DIE SHOPS CHANGING BEFORE Shops were poorly lit & unorganized Machines degrading Machine Controls antiquated Extensive manual intervention required for job set up Large investment in CMM AFTER Safety is a HIGH priority Shops are well organized & focused on energy conservation initiatives Restoration of machine conditions Automated sequencing Low cost/high technology scanning

7 PRESS TECHNOLOGY

8 TECHNOLOGY New Material Lightweight Lightweight Rust resistant Strong Challenges with Roll form Aluminum formability & slivers Magnesium application High strength Low formability (tool UHSS wear/larger Hot Stamp springback) application AHSS Boron Steel Minimal springback

9 TECHNOLOGY New Processes Cost effective Complex forming Complex forming Consistent thickness Strength Hydroforming Roll Forming High volume applications Closer tolerances New Opportunity Hot Forming to Build these Tools! Laser Blanking Lower tool costs Improved material utilization Quality enhancement

10 TALENT Increasing deficit of knowledge in Die Engineering and Die Construction

11 TALENT Scarcity of stamping experience and technical knowledge effecting all manufacturing and vehicle launch

12 TALENT Large loss with retiring work-force and shortage of trade based apprenticeship programs

13 TALENT Rapidly increasing demand for Employees with stamping manufacturing and die knowledge Design Pattern/ Castings Build Tryout

14 TALENT Where is it going? University opposed to Trade School/Apprenticeships Careers that offer: oflexible work arrangements; less rigidity olearning and development orapid progression / advancement oaccess to technology (digital world) oglobal opportunities Other Industries ohealth Care oinformation Technology oadvertising & Marketing oservice Industries (Hospitality & Retail)

15 TALENT Where is it going? What they don t know: ohighly technical equipment Simulation software Lasers Robots CNC Milling Servo press technology Etc ohow do we attract interest and showcase the appeal?

16 TALENT Future Candidate FCA s implementation of an Internal Die Rotational Program to develop the expertise Two year program that maximizes die knowledge through a very controlled rotation and review process Technical based rotation where the Employee focuses on learning the key technical details of the die business Focus on generating die skills for future leadership opportunities in our Stamping Plants and Stamping Technology Organization Reviewing opportunities to develop rotational program for stamping equipment engineering talent

17 CAN WE PROVIDE THE CYCLE? Drive down cost & improve overall competitiveness OEM New Program Opportunities Die Shops Die Shops Gain Efficiencies Added revenue to Die Shops Die Shops Invest in New Equipment & Opportunities Die Shops / Academia

18 SUMMARY The Industry is continuing to change Die Shops are being forced to diversify to compete in the Global Industry Technology is vastly changing Die & Stamping expertise is at a scarcity NEXT STEPS Today is the first step Action required from this point on