Manufacture Of Automotive Parts Research Articles

ROAD MAP OF DEVELOPMENT FOR PULL SYSTEM IN THAILAND SMALL AND MEDIUM AUTOMOTIVE PART MANUFACTURER

Since most of the Thai small and medium enterprises (SMEs) that manufacture automotive parts are facing problems in the production system inefficiency and the employees that do not understand the working system properly, accordingly, the production costs have risen up. This research aims to provide guidelines to develop a pull production system for small and medium enterprises that manufacture automotive parts using the lathe method in the production. Data was collected from the interview conducted with the employees at the factory which manufactures automotive parts by the lathe method and using the pull system efficiently in 5 factories in Thailand. The results from the study were analyzed, compiled, and made it suitable in order to develop the pull production system for the small and medium enterprises that manufacture the automotive parts by the lathe method in Thailand step by step. The results showed that in order to develop the production system to the pull system, the firms should operate according to the following steps: 1.) Set up the agency which is directly responsible for the system 2.) Train the employees 3.) Do 5S activity and visual control 4.) Conduct training across the production lines 5.) Bring Kanban and Kaizen cards into use 6.) Set standard for the production and once the production process of the enterprises is put into the pull system, it must be maintained to keep it as a standard. In addition, it improves the quality of production system of the enterprises. The advantage of adopting the pull production system is that the firm can quickly adjust the system according to the production procedures. Although the study focused only on the firms that use the lathe method, the researcher found that the study could be applied to the factories using other manufacturing methods.

Case—Production Scheduling at Falcon Die Casting

Falcon Die Casting Company (FDC) is an automotive parts manufacturer based in Ohio. FDC recently patented an innovative method of high volume die casting using traditional die casting machines. This patent was instrumental in FDC receiving a long term contract from a major automobile manufacturer for the bulk of its requirements for five key die cast items used in most of its automobiles. The customer provides FDC with an indication of the possible demand for the next 12 weeks with the understanding that demand beyond Week 2 is tentative and subject to change depending on auto sales during the preceding weeks. Table 1 shows the projected demand for the next 12 weeks. FDC can produce the parts on five die casting machines, each of which is capable of producing a subset of the parts as indicated in Table 2. For example, Part 1 can be produced only on Machines 1 and 2.

Effect of Semi-Solid Processing on Iron-Bearing Intermetallic Compounds in A380 Aluminum Alloy

Al-Si-Fe alloys are a general purpose of die casting alloys, widely used to manufacture automotive parts. Forming this alloy in semi-solid state can eliminate important problems in die casting process. In the present work, low superheat melt was employed to produce modified microstructure and non-dendritic A380 alloy feed stocks. The melt was cast on a cooling slope plate at 615 °C to obtain ingots. Then, ingots are thixoformed using a hydraulic press after heating them at 570 °C for 15 minutes, yielding a microstructure with predominantly α–Al globules, Si particles, and modified β-phase intermetallic compounds. The effect of semi-solid processing on the morphology, size, and distribution of iron-bearing intermetallics was studied. The results of image analysis of the samples showed that by using semi-solid method, the shape factor of α-Al phase improved, and iron containing intermetallics were modified in size and distribution. These changes in the aspect ratio and redistribution of the intermetallics improved the mechanical properties such as hardness of the products.

A friction model for loading and reloading effects in deep drawing processes

Deep drawing is one of the most widely-used forming processes to manufacture automotive body parts from sheet metal. In order to simulate deep drawing processes, a finite element (FE) method was used to predict formability. The accuracy of the FE simulation depends on the material models, numerical techniques, and contact algorithms. Despite the fact that the contact conditions between the tool and sheet material influences the coefficient of friction in forming processes, the coefficient of friction is often treated as a constant Coulomb friction coefficient in FE simulations. However, a friction model based on local contact conditions and surface topography is required to improve forming predictability. There is growing interest in developing contact models to predict the nature of friction conditions for use in FE calculations. In deep drawing processes, the sliding contact predominantly occurs in the blank holder region between the tool and sheet material. The contact pressure in the blank holder is non-uniform due to bending and material compression which vary depending on tool geometry. The sheet metal surface is subjected to repeated contact during sliding, which in turn affects the local friction conditions. The objective of this paper is to develop a sliding friction model for mixed modes of surface deformation. The deterministic approach used in the current model includes the roughness of both the sheet material and the tool. The sheet material is subject to an asperity flattening process. Further, the tool surface indents into the sheet material under normal loading. The geometry of the asperities is characterized by an elliptical paraboloid shape to better calculate the load-dependence of friction. The model has been compared with data from experiments using a rotational friction tester under multiple loading conditions.

The Potential Use of <i>Tacca leontopetaloides</i> as Green Material in Manufacturing Automotive Part

The use of thermoplastic elastomers (TPE) in making parts of the vehicle such as a weather strip at the door and car window, floor mat, and dashboard is widespread. The commonly being used as in automotive parts manufacturing is styrene based TPE. Styrene based TPE released harmful gas, volatile organic compound (VOC) to the environment when it expose to the high temperature. Therefore, the new material with properties of thermoplastic elastomers is made from Natural rubber blend with localTacca leontopetaloidesstarch and silica extracted from rice husk (as filler). Investigation on the mechanical properties by using Universal Testing Machine (UTM) found that the green material produced has potential to replace the existing floor mat used in automotive production. Indeed, when the starch was plasticized by glycerol and the volume of Natural rubber was varies, the value of tensile strength of green material produced was higher compared with existing floor mat. The VOCs released when its expose to the high temperature was much lower than the existing floor mat used. On top of that,Tacca leontopetaloidesstarchhas potential to create low cost of new green materials in manufacturing of automotive parts.

Application of mechanical trimming to hot stamped 22MnB5 parts for energy saving

An energy-saving mechanical trimming technology for hot stamped ultra high strength steel sheets is suggested in this study, in which the sheet thickness on the desired trim line is reduced by hot half-trimming at the same time as hot stamping, and the half-trimmed part is subsequently fully trimmed by mechanical trimming. Effectiveness of the proposed process has been investigated by FE-simulation and experiment. In this process, the hot half-trimming depth in hot stamping and the clearance between the punch and die in mechanical trimming were considered to be the main process parameters determining trimmed surface quality, trimming load, and tool wear. A high-quality trimmed surface, as compared with that produced by conventional cold trimming, can be achieved with a large hot half-trimming depth in hot stamping and small clearance in mechanical trimming. It was also shown that production time and cost can be reduced considerably by mechanical trimming using hot half-trimming, with low probability of tool chipping and reduced tool wear, as compared to conventional cold trimming and laser cutting processes. Therefore, mechanical trimming using hot half-trimming as proposed in this study can replace the high energy- and production time-consuming laser cutting process in the mass manufacturing of automotive parts.

The fit of planning methods for the part manufacturing industry, a case study

This paper investigates the specific planning environment of an automotive part manufacturer and characterizes this environment based on variables regarding the product, its demand and the manufacturing process. The fit of different planning methods, namely material requirements planning, reorder point, cyclic planning, kanban, and heijunka to this specific planning environment is analyzed and evaluated by exploratory research. The results show that different product characteristics make it hard to apply a single planning method. None of the investigated methods show the ability to cover the complex requirements of a combined planning environment of two partly divergent product types with a deep value chain.

Guest editorial of “Intelligent logistics and supply chains”

Information and communication technology (ICT) has been considered as an enabling tool for having more effective and efficient operations in the management of logistics and supply chains for many years. Various information and communication technologies are used to improve performance of the logistics and supply chain network, such as ‘‘data mining’’, ‘‘radio frequency identification (RFID)’’, ‘‘machine learning’’, ‘‘smart transportation’’. While ICT systems are vital components in logistics and supply chains, their successful management rests on intelligent and integrated decision making throughout the logistics network. Intelligent decision technologies are applied to collect and store real-time data and then analyze and interpret the data and information of product, inventory, manufacturing and sales to discover useful knowledge for making better operation and management decisions. Advanced simulation and optimization of planning and scheduling systems are also used for improvement of inventory, production, procurement, and distribution planning. Intelligent agents can communicate with different partners in the supply chain, assist in collecting information, share product information, negotiate prices, and distribute alerts throughout the logistics and supply chains networks. Many artificial intelligence (AI) technologies or systems have been implemented recently or are currently in the stage of implementation. We arranged the 3rd International Workshop of Advanced Manufacturing and Automation (IWAMA 2013) on 27–28th October, 2013 at Norwegian University of Science and Technology, Norway. The topics of IWAMA 2013 focused on: (1) intelligent manufacturing technologies; (2) intelligent logistics and supply chains; and (3) intelligent diagnosis and prognosis of wind turbines. After the workshop, we carefully select good papers and ask the authors to modify and extend their papers for further publishing as two special issues in Advances in Manufacturing: (1) Intelligent Manufacturing Technologies, and (2) Intelligent Logistics and Supply Chains. This is the second special issue and it is organized as the following: Chapter 1 presents review and analysis of ontology based interoperability solutions within textile supply chain. Chapter 2 describes the development of intelligent and integrated RFID (II-RFID) system for improving traceability and visibility of manufacturing. A new method of integrating adaptive sliding window and Euclidian distance for filtering RFID unreliable data is presented in Chapter 3. Chapter 4 investigates front-load effects of product development using system dynamics in order to approach lean production development. Chapter 5 describes an industrial case of a Norwegian supplier of ship equipment for realizing automation process in the ETO production situation. Chapter 6 presents incentive regulation of banks on third party logistics enterprises in principal-agent-based inventory financing. Chapter 7 shows a framework for real time production planning and control. Chapter 8 investigates the specific planning environment of an automotive part manufacturer and characterizes this environment based on variables regarding the product, its demand and manufacturing process. Chapter 9 deals with order batching problem, which has a major effect on the efficiency of warehouse operation in logistics in order to Y. Wang School of Material, The University of Manchester, Manchester, UK

Application of Quenching and Partitioning (Q&P) Processing to Press Hardening Steel

Press hardening steel (PHS) has been increasingly used for the manufacture of structural automotive parts in recent years. One of the most critical characteristics of PHS is a low residual ductility related to a martensitic microstructure. The present work proposes the application of quenching and partitioning (Q&P) processing to improve the ductility of PHS. Q&P processing was applied to a Si- and Cr-added Q&P-compatible PHS, leading to a press hardened microstructure consisting of a tempered martensite matrix containing carbide-free bainite and retained austenite. The simultaneous addition of Si and Cr was used to increase the retained austenite fraction in the Q&P-compatible PHS. The Q&P processing of the PHS resulted in a high volume fraction of C-enriched retained austenite, and excellent mechanical properties. After a quench at 543 K (270 °C) and a partition treatment at 673 K (400 °C), the PHS microstructure contained a high volume fraction of retained austenite and a total elongation (TE) of 17 pct was achieved. The yield strength (YS) and the tensile strength were 1098 and 1320 MPa, respectively. The considerable improvement of the ductility of the Q&P-compatible PHS should lead to an improved in-service ductility beneficial to the passive safety of vehicle passengers.

자동차 경량 부품 제조를 위한 Al-Cu-Mg 분말 합금의 소결 및 열처리 특성

Lightweight materials such as aluminum and magnesium have recently received much attention in the automotive industries because of environmental and fuel-efficiency concerns. Using the powder metallurgy (PM) process for these materials creates significant opportunities for the cost-effective manufacture of lightweight automotive parts. In the present study, an Al-Cu-Mg alloy was fabricated using conventional PM processes. Primarily, the effects of the alloying elements on the sintering characteristics and mechanical behavior after heat treatment were investigated. A microstructural analysis was performed using an optical microscope and a scanning electron microscope to investigate the behavior of liquid phase sintering, including the formation of precipitates. The dependence of the mechanical behavior on the alloying elements was evaluated based on the transverse rupture strength.

Design and process optimization of polymer filling for bevel guard based on numerical analysis

Injection molding has been widely used in the manufacturing of various polymer products, including housewares, home appliances, and automotive parts. A disposable medical device based on polymeric material at a low cost is another important area for injection molding. The numerical analysis was performed to predict the potential problem, often occurring during the manufacturing process of the medical device. Computer-aided engineering model was developed using industry-standard molding software, MOLDFLOW®. The flow pattern of the molten polymer was investigated in the replication of butterfly shaped Catheter Support for various catheterization. The flow pattern and temperature distribution of the molded part were investigated through a series of analysis. The results of analysis with original design predicted non-uniform polymer flow with a poor weld line, unbalanced cavity filling, and uneven temperature distribution of the part. An appropriate gate location to achieve uniform flow pattern for mold filling was determined on the base of the predicted results and experience, considering the performance of the product and limitation of the production.

DEA를 활용한 자동차부품 기업의 효율성 평가에 관한 연구

최근 글로벌 경기 침체로 인한 완성차 수요 급감으로 세계 자동차부품산업이 위기에 직면해 있다. 미국 자동차부품업체들은 2008년 4분기 이후 대규모 적자를 기록 중에 있으며, 고성장세를 유지하던 일본 및 유럽 부품업체들도 경영실적이 크게 악화되었다. 국내 자동차부품기업도 이러한 영향에서 벗어나기가 어려울 것으로 예상된다. 본 연구는 자동차부품 중소기업 중 상장된 25개의 업체를 대상으로 DEA분석기법을 활용하여 각 기업에 대한 상대적 효율성을 분석하였다. 효율성분석결과 CCR모델에서는 전체 25개 기업 중 6개 기업이 효율적인 것으로 나타났지만 기업의 규모를 고려한 효율성 분석인 BCC분석결과 12개 기업이 효율적으로 운영하는 것으로 나타났다. 그리고 25개의 자동차부품기업 중 효율성이 1인 기업이 DMU 1, 5, 7, 10, 18, 24로, 다른 자동차부품기업이 상대적으로 벤치마킹을 해야 할 대상은 DMU 1, 10, 24로 나타났다. 본 연구의 결과를 바탕으로 국내 자동차부품기업이 나가야 할 방향을 제시하고, 국내 자동차부품기업의 효율성을 실증적으로 분석하여 경영효율성을 제고함으로써 향후 자동차부품기업을 경영하는데 있어 매우 중요한 정보를 제공할 것으로 기대된다. Due to the recent global recession, the car industry demand levels have plummeted which led to a crisis in the automotive parts industry for the first time in history. Since the fourth quarter of 2008, the automotive parts manufacturers in America have faced a record loss and those in Japan and Europe who also had a strong track record are facing a weak economy. In addition, the domestic automotive parts industry is also affected by the global economic crisis. This research is that the relative efficiency analysis utilizing the DEA has done on the object of 25 small and medium-sized automotive parts manufacturers publicly listed, As the efficiency analysis result 6 of 25 manufacturers are efficient in CCR model and 12 manufactures have shown efficiency in BCC model, the efficiency analysis in consideration of the manufacturer size. The manufacturers with efficiency 1 in 25 manufacturers are DMU 1, 5, 7, 10, 18, 24 and the relatively benchmarking objects in other manufactures are DMU 1, 10, 24, Based on the results of this research, a direction to the domestic automotive parts manufacturers as well as a significant information will be provided in managing the companies in the future by the improvement of management efficiency through the practical efficiency analysis.

Approach of Measuring System Analyses for Automotive Part Manufacturing

Approach of Measuring System Analyses for Automotive Part Manufacturing

Electrically assisted blanking using the electroplasticity of ultra-high strength metal alloys

The electroplastic tensile behavior of ultra-high strength steels (UHSS) subject to a single pulse of electric current is briefly introduced, and electrically-assisted (EA) blanking, which utilizes this electroplastic characteristic, is suggested. The experimental result shows that the blanking load of EA blanking is clearly lower than that of blanking with local resistance heating, which is lower than that of cold blanking. No significant change in material properties was observed in the EA blanked parts at the electric energy densities selected in the present study. EA blanking or trimming is expected to minimize or even eliminate the need for expensive and time-consuming laser trimming in the manufacture of automotive parts using UHSS.

MICROALLOYED STEELS FOR THE AUTOMOTIVE INDUSTRY

Two major drivers for the use of newer steels in the automotive industry are fuel efficiency and increased safety performance. Fuel efficiency is mainly a function of weight of steel parts, which in turn, is controlled by gauge and design. Safety is determined by the energy absorbing capacity of the steel used to make the part. All of these factors are incentives for the U.S. automakers to use both Highly Formable and Advanced High Strength Steels (AHSS) to replace the conventional steels used to manufacture automotive parts in the past. AHSS is a general term used to describe various families of steels. The most common AHSS is the dual-phase steel that consists of a ferrite-martensite microstructure. These steels are characterized by high strength, good ductility, low tensile to yield strength ratio and high bake hardenability. Another class of AHSS is the complex-phase or multi-phase steel which has a complex microstructure consisting of various phase constituents and a high yield to tensile strength ratio. Transformation Induced Plasticity (TRIP) steels is another class of AHSS steels finding interest among the U.S. automakers. These steels consist of a ferrite-bainite microstructure with significant amount of retained austenite phase and show the highest combination of strength and elongation, so far, among the AHSS in use. High level of energy absorbing capacity combined with a sustained level of high n value up to the limit of uniform elongation as well as high bake hardenability make these steels particularly attractive for safety critical parts and parts needing complex forming. A relatively new class of AHSS is the Quenching and Partitioning (Q&P) steels. These steels seem to offer higher ductility than the dual-phase steels of similar strengths or similar ductility as the TRIP steels at higher strengths. Finally, martensitic steels with very high strengths are also in use for certain parts. The most recent

Process improvement through Six Sigma with Beta correction: a case study of manufacturing company

This article discusses the successful implementation of Six Sigma DMAIC (Define–Measure–Analyse–Improve–Control) methodology along with Beta correction technique in an automotive part manufacturing company. The implementation of Six Sigma approach resulted in reduction of process capability-related problems and improved the first pass yield from 94.86 % to 99.48 %. After studying the baseline performance of the process, a brainstorming session was conducted with all stakeholders of the process for identifying the potential causes of the problem. Data were collected on all the identified potential causes and various statistical analyses like regression analysis, hypothesis testing, and Taguchi methods were performed for identifying the root causes. Solutions were identified and implemented for the validated root causes, and results were observed. The Beta correction technique was introduced for monitoring the process in the control phase. Implementation of Six Sigma methodology with Beta correction technique had a significant financial impact on the profitability of the company. An approximate saving of US$87,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. This study contributes uniquely by elucidating the synergistic impact of Beta correction for greater effectiveness of Six Sigma programmes in the engineering industry.

Temperature dependent properties of heat treated aluminium alloys

The mechanical properties of different aluminium alloys used in the manufacture of power train automotive parts were studied. The alloys were cast in wedge shape ingots that promote a one-dimensional solidification gradient. Tensile samples were machined from bars that were cast with different degrees of microstructural refining and were heat treated at times and temperatures that depended on their composition. The mechanical properties were measured from samples that had been held for 200 h within the temperature range of 25 to 300°C. It was found that the increase of Cu in alloys of the Si–Mg type alloys enhanced the mechanical properties above room temperature. The best properties were found in the Al–Cu alloy.

Niobium Containing Advanced High Strength Steels for Automotive Applications – Processing, Microstructure, and Properties

Two major drivers for the use of advanced steels in the automotive industry are fuel efficiency and increased safety performance. Fuel efficiency is mainly a function of weight of steel parts, which in turn, is controlled by gauge and design. Safety is determined by the energy absorbing capacity of the steel used to make the part. All of these factors are incentives for the automobile manufacturers to use Advanced High Strength Steels (AHSS) to replace the conventional steels used to manufacture automotive parts in the past. AHSS is a general term used to describe various families of steels. The most common AHSS is the dual-phase steel that consists of a ferrite-martensite microstructure. These steels are characterized by high strength, good ductility, low tensile to yield strength ratio and high bake-hardenability. Another class of AHSS is the complex-phase or multi-phase steel which has a complex microstructure consisting of various phase constituents and a high yield to tensile strength ratio. Transformation Induced Plasticity (TRIP) steels is another class of AHSS steels finding interest among the U.S. automakers. These steels consist of a ferrite-bainite microstructure with significant amount of retained austenite phase and show the highest combination of strength and elongation, so far, among the AHSS in use. High level of energy absorbing capacity combined with a sustained level of high n value up to the limit of uniform elongation as well as high bake hardenability make these steels particularly attractive for safety critical parts and parts needing complex forming. A relatively new class of AHSS is the Quenching and Partitioning (Q&P) steels. These steels seem to offer higher ductility than the dual-phase steels of similar strengths or similar ductility as the TRIP steels at higher strengths. Finally, martensitic steels with very high strengths are also in use for certain parts. The most recent initiative in the area of AHSS is the so-called 3rd Generation AHSS. These steels are designed to fill the region between the dual-phase/TRIP and the Twin Induced Plasticity (TWIP) steels with very high ductility at strength levels comparable to the conventional AHSS. Enhanced Q&P steels may be one method to achieve this target. Other ideas include TRIP assisted dual phase steels, high manganese steels and higher carbon TRIP type steels. In this paper, some of the above families of advanced high strength steels for the automotive industry will be discussed with particular emphasis on the role of niobium.

Achieving Superior Motivation and Performance: The Case of the Acquisition and Transformation of CAZEL in Mexico

This article explores some of the prevailing change management methodologies to determine their applicability and convenience as transformational tools. The authors propose a practical model for change and explore the factors affecting employee's motivation during and after a business transformation process. The methodology is reviewed while analyzing the successful results achieved in the recent acquisition and transformation of “Industrias Cazel” (CAZEL), an automotive-parts manufacturer in Mexico. Prior to the transformation, CAZEL successfully implemented a quality program, achieved high marks in terms of the operating business indicators used at the time, and had the appropriate information technology platforms to support the business; however, it still faced the challenge of aligning the organization strategically and culturally amid a multitude of people issues, which had brought it close to bankruptcy. The aim of this article is to harness the best of the various disciplines found in the literatur...

Impact of parameters on the process response: A Taguchi orthogonal analysis for laser engraving

Compared to conventional methods, laser engraving is the most effective technique in the machining of hard materials that have a complex geometry. Therefore, laser based machining is widely used in many industries like mold making, and the manufacture of automotive, electronics and biomedical parts. The present study investigates the machinability of hard metal produced with powder metallurgy and puts forward a new approach relating to the laser engraving of P/M metals. The main objective of this study is to determine the impact of laser engraving process on Vanadis 10. For this purpose, three process parameters – namely effective scan speed, frequency, and laser effective power – were correlated with the surface roughness (Ra) and engraving depth (D). The Taguchi and linear regression were used in the analysis. The experiments were performed in accordance with an L9 orthogonal array. Based on the S/N ratio for Ra and D, the optimal condition was found as SS3F2P1 for Ra and SS1F2P3 for D. It was found that scan speed has a statistically significant effect on both Ra and D. Furthermore, a mathematical model for both Ra and D was established and estimated using linear regression. The model was also tested using different experimental conditions than existing ones. The results obtained from the new experimental conditions show that the predicted models could explain the process.