Ensuring Manufacturing Infrastructure Readiness. Dr. Paul E. Krajewski General Motors Company GALM 2013

Transcription

1 Ensuring Manufacturing Infrastructure Readiness Dr. Paul E. Krajewski General Motors Company GALM 2013

2 Outline Define Scope of Problem Key Questions Material Product Development Forming Assembly / Joining Painting Execution Summary

3 Back to the Future 1909 Ford Model T Touring Car Aluminum Hood, 1915 Model T

4 It is difficult to define manufacturing lightweighting approaches.

5

6 Audi A8 Aluminum_Space_Frame_jpg_667x667_q100.jpg

7 Plastics Omnium et- inovation- auto

8 MIXED MATERIALS SOLUTIONS

9 ATS Material Selection Mild Steel Bake Hardenable HSLA Dual Phase Martensitic PHS Al

10

11 BMW i3 & i8 Carbon Fiber Aluminum

12 Audi Mixed Materials Aluminum Carbon Fiber

13 Key Light- weighting Questions Need to define overall strategy What vehicle segment / price point / volume? What is the value of mass on the program? Global or regional execution? Which materials and parts? Where will parts be produced? Make vs. Buy What assembly / joining technique will be used?

14 Manufacturing Value Stream

15 Material Raw material availability geography Conversion to sheet / extrusion / ingot Preparation for forming pretreatment Blanking vs. Coils um_section_x3.jpg

16 Key Material Issues PHS Prototype infrastructure Material suppliers with Zn coating Aluminum Heat treat capacity Structural casting infrastructure Magnesium Limited supply base for low cost sheet and HPDC 90% of material produced in China Composites Low density SMC Class A / Painting Dimensional stability / fit Carbon Fiber Overall Industry capacity low. North American supply base limited.

17 Lightweight Material Capacity Aluminum 2012 NA capacity for heat treated Al sheet 90kT. An AIV with 400,000 APV requires 90 kt. Carbon Fiber A carbon fiber intensive body and closures at 200,000 APV would consume global fiber capacity.

18 Product Development Issues Overall lack of experience with lightweight materials. Lack of design for manufacturing (DFM) information. CAE database for materials and joints. Opportunity for industry collaboration Develop best practices. Acoustic management.

19 Primary Forming PHS Hot forming lines required Typically done in supply base Aluminum Can use existing steel infrastructure Need more dies (5-6) different lubricants. Scrap segregation Magnesium Requires thermal assisted forming Die casting infrastructure limited. Composites SMC supply base limited. Long cycle time Improved formability compared to steel/al Carbon Fiber North American supply base limited Long cycle time

20 Need to develop new processes to enable mixed material vehicle executions. Decide whether performing in- house or at suppliers Accurately forecast usage to assure capacity

21 Form Press Hot Tool Cleaning Robot Form Tool Destack Robot Operator Station & Ergonomics Exit Conveyance Cooling Fixture Location Press Automation Blank Pre-Heater Blank Presentation Fixture Blank Stack

22

23 Secondary Forming Trimming Clinching Hemming AZ31 Magnesium BENDING MAGNESIUM FOR AUTOMOTIVE

24 Assembly / Joining PHS Need new welding, fastening and bonding techniques Aluminum Spot welding compatible with steel? Riveting Adhesive bonding without pretreatment Magnesium Need heated clinching / fastening Corrosion isolation. Composites/Carbon Fiber Closure assembly at Tier supplier Need bonding / fixturing experience Surface effects / read- through

25 Painting Aluminum and PHS can be processed through conventional paint lines. Al / Steel mix can require varying phosphate bath chemistry Paint bake temperature can affect aluminum properties and will affect composites. Magnesium need to be coated prior to painting/assembly Composites usually painted offline and installed in General Assembly.

26 The easiest approach to enabling the use of lightweight materials is a dedicated plant.

27 Bowling Green Assembly

28 Corvette Z06 Hydroformed Al Roof Bow Mg Roof Frame Ti Valves and Connecting Rods Mg Engine Cradle Hydroformed Al Frame Rails Carbon Fiber Floor Pan

29 Corvette Stingray

30 Aluminum Frame

31

32 Tube Hydroforming

33 Composite Painting

34 Corvette Assembly

35 Camaro

36 Camaro ZL1

37 Global Multi- Plant Platform Key Issues/Questions: Common execution or regional variation Model changeover strategy Are multiple architectures built in same plant Dedicated or flexible body shop

38 Summary The increased use of lightweight materials will require capital investment and increased piece cost. Impact can be minimized with clear strategy and long term vision. A long term strategy is essential to making sure the value chain is ready for execution.