INNOVATIONS & SUSTAINABILITY IN THE DEVELOPMENT OF LEATHER SEAT COVERS TRENDS AND INNOVATIVE DESIGN- AND VALIDATION METHODS

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1 Dr. Constanze Pentzel Senior Manager R&D Body and Interior Trim Dr. Andreas Dyla Senior Manager Material, Processing, Comfort INNOVATIONS & SUSTAINABILITY IN THE DEVELOPMENT OF LEATHER SEAT COVERS TRENDS AND INNOVATIVE DESIGN- AND VALIDATION METHODS

2 PRODUCT LAUNCHES OF BMW GROUP IN 2011 THE TAKE-RATE FOR LEATHER IS AND REMAINS HIGH MINI Coupé MINI Roadster BMW 1series Coupé ActiveE BMW 1series M Coupé BMW 6series Coupé BMW 1series 5-Door BMW 3series 5-Door BMW ActiveHybrid 5 Rolls Royce Ghost EWB BMW X1 CN BMW M5 Sedan

3 CHALLENGES TO BE SOLVED BY BMW, 1ST AND 2ND TIER SUPPLIERS AS ONE TEAM Trends and requirements Expectations of our customers International market requirements Consequent achievement of quality targets Reduction of quality topics and HC-emissions Process stability Logistics chain Innovations in development process and validation Analysis of life time cycle Preventive quality work in the development process 3D-validation and simulation

4 THE EXPECTATIONS OF OUR CUSTOMERS ON LEATHER TRIM ARE CHANGING General trends Wellness and well-being Natural leather Weight Sustainability Internationalisation Role of markets is moving Sit-in feeling is important for buying decision Social status and age of customers is changing Other preferences for materiality (lounge-feeling) Bright leather colours, smooth leather Outlook into the future Autonome driving Differentiation, individualisation, applications HC-emissions

5 APPROX. 60% OF QUALITY TOPICS WITH LEATHER SEAT COVERS ARE CAUSED BY LEATHER QUALITY Abrasion Wrinkles / Waviness Ruptures Sit-In Wrinkle It is our common responsibility to avoid such quality topics

6 EXAMPLE HC EMISSIONS: SOLUTION CAN ONLY BE WORKED OUT TOGETHER IN DIALOGUE Analyzed substances TVOC Formaldehyde Acetaldehyde NMP/NEP Benzene N-Nitrosamines Further actions Analysis of deviations Definition of measures for compliance with limiting values Realization of measures Premise No change in leather properties allowed

7 THE LEATHER PRODUCTION PROCESS IS ONLY A SMALL PART OF LIFE TIME CYCLE, BUT INFLUENCES ALL FOLLOWING PHASES UNTIL END OF CUSTOMER USE Product development process of vehicle Natural phase and leather production Leather processing (cutting, lamination ) Seat cover production Production assembly Customer usage Knowledge and competence network Decisive contents for all following life phases

8 EXAMPLE LOGISTICS CHAIN: MASTERING OF STABILITY IN A COMPLEX PRODUCTION- NETWORK IS A BIG CHALLENGE Sub-suppliers tanneries Tanneries Punching shops (only seat cover) Sewing shops Seat assy shops Vehicle final assembly Overview picture for the leather seat logistics progess chain of 5, 6 and 7 series Process chains of other leather products in vehicle

9 THE EARLIER POTENTIAL SOURCES OF DEFECTS CAN BE ELIMINATED, THE MORE ROBUST THE PRODUCT WILL BE AT SOP Application and utilization Preventive Q-work Precise definition of beam barriers for new vehicle projects for sustainable stoppage of field problems Reactive Q-Work Quicker problem solution by quick access to existing knowledge Knowledge and competence network Nature phase (breed, origin, food, breeding, keeping, climate, logistics...) Leather production (Water shop, tannery, drying, finish, logistics...) Leather Seat cover Knowledges-/CompetenceNetwork processing (cutting ) production Production final assembly Customer Change from reactive to proactive measures at product development

10 THE 3D-VALIDATION OF ABRASION AND SIT-IN WRINKLE IS STATE-OF-THE-ART Special fabric (jeans-style) New 500 load cycles 1000 load cycles

11 THE EARLY SIMULATION OF LEATHER ON THE FINISHED PRODUCT REDUCES LATER VALIDATION LOOPS ON HARDWARE Seat cover A Simulation Seat cover B Interaction simulation and robot

12 SUMMARY LEATHER IS A NATURAL PRODUCT AND VERY IMPORTANT FOR THE SUCCESS OF OUR PRODUCTS The product leather needs further development: Naturalness, weight, sustainability International market requirements have to be implemented Quality topics to be solved from an integral point of view together with all partners Product- and process stability have to be pushed Realize the best possible property profile for this natural product To reach these targets we appreciate an open and cooperative relationship to all partners which can offer a contribution to further optimization