Consapevolezza e qualità in process: applicazine della UNI ISO/TS 16949:2009 nel reparto produttivo di pressatura in Sinteris Spa

Lo studio nasce dalla necessità di verificare l’applicazione di alcuni punti della ISO/TS 16949:2009 nel reparto di pressatura dell’azienda. Era importante valutare il livello di consapevolezza dei dipendenti relativamente al problema qualità in un’azienda automotive. Perciò, a partire dalla normativa, è stata fatta un’Indagine di Consapevolezza tra tutti i dipendenti il cui lavoro ha influenza sulla qualità del processo produttivo e del prodotto realizzato. Inoltre, serviva controllare se la logistica del reparto di pressatura fosse adeguata per permettere agli operatori di svolgere al meglio l’ autocontrollo, ossia un controllo in process delle quote geometriche e dimensionali durante la produzione di serie. È stata verificata l’adeguatezza delle unità di carico per la movimentazione dei prodotti, sia a livello logistico che di carico di lavoro per chi le deve movimentare. È risultato che le UdC attualmente in uso, ossia carrelli mossi manualmente, non possono essere sostituite, ma le si può rendere più maneggevoli cambiandone le ruote. Si è studiato il carico di lavoro del reparto di pressatura, per valutare se fosse possibile introdurre misure che diano la possibilità agli operatori di reparto di svolgere i controlli in process con più accuratezza, ipotizzando l’introduzione di una figura specifica, l’Operatore dell’Autocontrollo, che possa occuparsi solo di questo incarico, sollevando gli altri operatori da tale incombenza. Infine, ci si è posti il problema di ridurre l’utilizzo dei carrelli elevatori all’interno del reparto. È risultato necessario mantenerne l’uso per poter garantire la grande flessibilità nella produzione di quest’azienda, ma si è ipotizzato di separare il reparto in due diverse zone al momento del rinnovo del parco macchine, in modo da eliminarne l’utilizzo in una delle due zone e concentrarlo nell’altra, rendendoli indispensabili solo per un determinato tipo di produzione che si svolga in un settore ben definito del reparto.

A long-term energy efficiency prediction model for the Brazilian automotive industry

According to law number 12.715/2012, Brazilian government instituted guidelines for a program named Inovar-Auto. In this context, energy efficiency is a survival requirement for Brazilian automotive industry from September 2016. As proposed by law, energy efficiency is not going to be calculated by models only. It is going to be calculated by the whole universe of new vehicles registered. In this scenario, the composition of vehicles sold in market will be a key factor on profits of each automaker. Energy efficiency and its consequences should be taken into consideration in all of its aspects. In this scenario, emerges the following question: which is the efficiency curve of one automaker for long term, allowing them to adequate to rules, keep balancing on investment in technologies, increasing energy efficiency without affecting competitiveness of product lineup? Among several variables to be considered, one can highlight the analysis of manufacturing costs, customer value perception and market share, which characterizes this problem as a multi-criteria decision-making. To tackle the energy efficiency problem required by legislation, this paper proposes a framework of multi-criteria decision-making. The proposed framework combines Delphi group and Analytic Hierarchy Process to identify suitable alternatives for automakers to incorporate in main Brazilian vehicle segments. A forecast model based on artificial neural networks was used to estimate vehicle sales demand to validate expected results. This approach is demonstrated with a real case study using public vehicles sales data of Brazilian automakers and public energy efficiency data.

Terminal defect analysis and classification methodology for automotive industry

The impact of end customer quality complaints with direct relationship with automotive components has presented negative trend at European level for the entire automotive industry. Thus, this research proposal is to concentrate efforts on the most important items of Pareto chart and understand the failure type and the mechanism involved, link and impact of the project and parameters on the process, ending it with the development of one of the company’s most desired tool, that hosted this project – European methodology of terminals defects classification, and listing real opportunities for improvement based on measurement and analysis of actual data. Through the development of terminals defects classification methodology, which is considered a valuable asset to the company, all the other companies of the YAZAKI’s group will be able to characterize terminals as brittle or ductile, in order to put in motion, more efficiently, all the other different existing internal procedures for the safeguarding of the components, improving manufacturing efficiency. Based on a brief observation, nothing can be said in absolute sense, concerning the failure causes. Base materials, project, handling during manufacture and storage, as well as the cold work performed by plastic deformation, all play an important role. However, it was expected that this failure has been due to a combination of factors, in detriment of the existence of a single cause. In order to acquire greater knowledge about this problem, unexplored by the company up to the date of commencement of this study, was conducted a thorough review of existing literature on the subject, real production sites were visited and, of course, the actual parts were tested in lab environment. To answer to many of the major issues raised throughout the investigation, were used extensively some theoretical concepts focused on the literature review, with a view to realizing the relationship existing between the different parameters concerned. Should here be stated that finding technical studies on copper and its alloys is really hard, not being given all the desirable information. This investigation has been performed as a YAZAKI Europe Limited Company project and as a Master Thesis for Instituto Superior de Engenharia do Porto, conducted during 9 months between 2012/2013.

Flexible roll forming of an automotive component with variable depth

Roll forming is a cost and energy efficient process for the manufacture of Ultra High Strength Steel (UHSS) structural and crash components in the automotive industry. The conventional roll forming process is limited to component having constant cross-section, while the recently deveoped Flexible Roll Forming (FRF) process allows the production of components in which the section varies over the length of the aprt; this permits optimization in terms of strength and weight. There has been an uptake in FRF in the heavy vehicle industry for the production of long and high strength structural parts, but passenger car bodies are more complex and generally parts require variations in width and also in depth. The widespread application of FRF in the automotive industy therefore requires the forming of components that have intricate variations in profile depth over the length of the part.
This work is a first comprehensive study of the FRF of high strength structural components with variable depth. For this, the FRF of an automotive bumper section is analyzed numerically using the commercial software package COPRA® FEA RF. A detailed analysis of the distribution and history of plastic strain in longitudinal, transcerse and thickness directions is performed and related to the shape defects observed in the proecss. The analysis shows that when forming variable depth components, zones of compressive longitudinal strain exist that lead to wrinkling defects. These can be reduced by applying additional flange contact during the operation. In general the current work suggests that the FRF of high strength components with variable depth is possible and can compete with other forming methods currently used in the automotive industry.

A Best Practice Process for Fleet Safety Training

This paper outlines a process for fleet safety training based on research and management development programmes undertaken at the University of Huddersfield in the UK (www.hud.ac.uk/sas/trans/transnews.htm) and CARRS-Q in Australia (www.carrsq.qut.edu.au/staff/Murray.jsp) over the past 10 years.