Automotive Design and Production

JUN 2013

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that allows them to not only run multiple models with a given facility, but to be able to adjust volumes as needed. "We have really clear standards around technology that provides fexibility for styling creativity, the ability to have mixed fexibility—to go up on one vehicle and down on another as the market swings—and to be able to introduce new models with our launch cadence without having to idle the plant," Hettle says. While Ford has long been using robotics in its assembly plants, Hettle explains that nowadays the focus is to use the equipment in ways that allows on-going fexibility within an operation without having to take the equipment down for reprogramming and retooling to accommodate diferent models. The trim and fnal department of an assembly plant has long been comparatively labor intensive (compared, say, to the body line, where robots are abundant). Hettle thinks it will remain that way, with automation being used where it helps with safety, ergonomics, or quality. "Many of the components in trim and fnal require fnesse, and we believe from a total cost and quality standpoint that the blend of people and machines is the right approach." One area where there is an increased amount of automation is at the "Customer Acceptance Line" (CAL), the fnal exit point of the assembly plant. Hettle says that they are using cameras and other sensors in conjunction with robots to perform a variety of checks and tests, from measuring the fushness of the sheet metal to assuring that the right badges for a particular vehicle are located in the appropriate spots to checking door eforts. Not only does this help assure that the vehicle being checked is right, but by accumulating the data related to a consistent problem (e.g., a door margin out of spec), they are able to go upstream in the process to make adjustments to solve that problem. Hettle thinks that CAL is absolutely essential for meeting the high quality standards that are now required. In fact, when asked what he believes is the most important emerging technology for vehicle build, "It would have to be the technology to validate quality. That will be the distinguishing factor in the end." The Future is Light. With manufacturing technologies from Schuler. When it comes to lightweight car construction, success depends on a strategic blend of a wide variety of materials, forming technologies and processes. Schuler is the world's only manufacturer of press systems to ofer a broad spectrum of solutions for cold forming highstrength steels, hot stamping and hydroforming, as well as processing aluminum and carbon fber-reinforced plastics. We are proud to annouce Schuler has won a prestigious 2013 Automotive News PACE Award for our innovative Hydroforming Global Die Design and Process. Learn more on our YouTube video: SchulerInc.com/LightDesign FORMING THE FUTURE 43

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