Ford to invest $733 million in southeastern Michigan plants
Ford's recently announced plan to invest $733 million in southeastern Michigan plants is part of a larger plan to invest $6.2 billion in U.S. plants by 2015. The single largest investment for southeastern Michigan will be $305 million for facility modernization, new press lines, a scrap conveyor system, and other machinery and equipment at the Dearborn Stamping Plant. Other area facilities slated for upgrades include Michigan Assembly Plant ($54.9 million), Flat Rock Assembly Plant ($161 million), Sterling Axle Plant ($86 million), Van Dyke Transmission Plant ($87.7 million), and Livonia Transmission Plant ($74.7 million). The planned investments in southeastern Michigan were announced by Ford Dec. 27.
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Ford will invest $87.7 million in its Van Dyke Transmission Plant for machinery and equipment to meet capacity expansions for its 6F35 and 6F50 transmissions.
Nissan charges up its new EV battery plant in Tennesee
Nissan recently began operations of its new advanced-battery plant in Tennessee that will supply the energy-storage devices for the Nissan Leafs to be produced at an adjoining vehicle-assembly plant. Regular North American production of the Leaf is to start at the automaker's Smyrna plant early in 2013. To date, the Leaf and its lithium-ion battery pack currently are made in Japan only. The first batteries produced in Smyrna for the 2013 Leaf have completed the required aging process and are ready to receive their first charge, the company said in a recent announcement. The plant is fully integrated, with raw battery cell materials coming in one end and finished battery packs going out the other (see accompanying image). Nissan has not yet released specifications for the 2013 Leaf and its battery pack. The Leaf will be assembled alongside the Nissan Altima and Maxima.
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The production process at Nissan's new U.S. battery plant begins with formation of electrode sheets.
Detailed FEV study shows the way to major vehicle mass savings
Significant vehicle mass reduction—up to 20%—is achievable if weight reduction is pursued as part of a "full-vehicle approach," according to a study by FEV Inc. released Dec. 13. The company used a 2010 Toyota Venza for its research because that model was used in an earlier, related study. The comprehensive phase-two study by FEV was conducted for the U.S. EPA. The previous study, by Lotus Engineering (go to www.sae.org/mags/aei/8512 to read more), was conducted for the International Council on Clean Transportation. That study did not address mass savings from the powertrain to the extent the new one does, nor did it use advanced CAE tools to judge the impact of mass-savings measures on safety, according to FEV. In both cases, the mass savings were to be achieved with no degradation in safety or other parameters. The new study shows that the body-in-white and closures offered the most mass reduction at 68.32 kg (150.62 lb), followed closely by suspension. Total mass savings of 18.3% (312 kg/688 lb) was achieved, and at a cost savings of $148 from manufacturing efficiencies.
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Advanced CAE tools were used as part of the comprehensive study that resulted in a report of 890 pages.
BMW and Boeing to collaborate on carbon-fiber materials
Two heavyweights in the automotive and aerospace industries are joining minds on lighter materials. BMW and Boeing on Dec. 12 announced they would do joint research on carbon-fiber recycling and share knowledge about the material and its manufacture. As part of the collaboration agreement, the two companies will also share carbon-fiber manufacturing process simulations and ideas for manufacturing automation. BMW in 2013 plans to introduce two models from its new i brand (i3 battery-electric and i8 plug-in hybrid) featuring bodies made of carbon-fiber-reinforced plastic. Boeing's new 787 Dreamliner aircraft is made up of 50% carbon fiber. The collaboration is the first ever between the two companies.
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The bodies of BMW's i brand models will use carbon-fiber-reinforced plastic. (Patrick Ponticel)
General Motors and partners open new plant in China
General Motors, SAIC, and Wuling Motors opened a new car plant Nov. 18 in Liuzhou, Guangxi Zhuang Autonomous Region, southern China. The three companies are partners in SAIC-GM-Wuling (SGMW). It was on the JV's 10th anniversary that the first car (a Baojun 630 midsize sedan) rolled out of the new $1.28 billion, 2-million-ft2 (200,000-m2) plant. Baojun is a passenger-car brand of SGMW. The joint venture also produces Wuling-brand minivans and minitrucks at other plants. SAIC holds a 50.1% stake in SGMW, GM 44.0%, and Wuling 5.9%. Annual capacity at the new plant is 400,000 units.
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A Baojun 630 midsize sedan was the first vehicle to roll out of the new SGMW plant Nov. 18.
Volvo ramps up production of world's first diesel plug-in hybrid
Volvo Car Corp. says it has successfully integrated production of what it claims is the world's first diesel plug-in hybrid into the assembly line with conventional models at its Torsland Plant in Gothenburg, Sweden. The company claims it is the first to accomplish such an integration. "The integration in the standard production flow gives the plug-in hybrid buyer the possibility to choose, in principle, all options available for the standard V60," said Peter Mertens, Senior Vice President Research and Development at Volvo Car Corp. The assembly line was rebuilt to accommodate production of the plug-in, which features 300 more parts than the conventional car models. After the first batch of 1000 MY2013 V60 Plug-ins are built, the plant will ramp up to as many as 6000 MY2014 units, according to the company.
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Sofia Nordgren and Apichat Khongkamnoed install the high-voltage cables (orange) and the cooling system for the V60 Plug-in's battery pack at Volvo's Torsland Plant in Gothenburg, Sweden.
Mazda to build subcompact for Toyota in Mexico
Mazda will build a Toyota-branded subcompact vehicle based on the Mazda2 in Mexico beginning in summer 2015, the two companies announced on Nov. 9. To be built at a pace of about 50,000 units annually, the vehicle will be sold mainly in North America. Production will take place at a new plant Mazda being built in Salamanca, state of Guanajuato, where the Mazda2 and Mazda3 will also be built. Plant capacity was originally planned at 140,000 units annually for the Mazda products only. but will be increased to accommodate the Toyota model. The companies did not release financial terms of the deal.
SAE offers new credential program for engineers
SAE International is introducing a personnel credentialing program that enables engineers, product development technicians, and associated personnel to earn a Certificate of Competency or Certification in the Design Review Based on Failure Modes (DRBFM) methodology. Created by industry professionals for industry professionals, the program was developed and segmented into three distinct levels to meet the needs of specific personnel. Exam questions align with the body of knowledge to address each of the three levels. The DRBFM Process and Application Certificate of Competency is designed for individuals who require training and validation of knowledge in DRBFM process methodology. Job roles include product engineers, manufacturing engineers, quality engineers, supplier quality engineers, validation and test engineers, and facilitators, trainers, and consultants in all industries. This credential requires completing an open-enrollment training course and passing an online exam. Registration is now open for the December 2012 offering of this program. For more information, contact SAE International at certification@sae.org or visit https://www.saecredentialingalliance.org/go/drbfm.
Allison and Dana license Fallbrook's NuVinci transmission technology
Dana Holding Corp. and Allison Transmission will use Fallbrook Technologies' Continuously Variable Planetary (CVP) technology in new products under a "strategic relationship" announced by the three companies Sept. 13. Fallbrooks' NuVinci CVP is a traction-based class of continuously-variable transmission that is scalable and adaptable. In the basic design, a set of rotating balls is located between the input and output components. Tilting the balls changes their contact diameters and varies the speed ratio. Compared to other current technologies, Fallbrook claims its is less complex, scales and packages more easily, and costs less to manufacture. Under the deal, Allison has exclusive rights to use the Fallbrook CVP technology to develop and commercialize primary drivetrain transmissions for Allison's end markets, which could include commercial vehicles, military applications, and certain off-highway and large stationary equipment. Under a separate agreement, Dana will hold an exclusive license to engineer and produce transmission components and other advanced powertrain solutions for passenger and certain off-highway vehicles in the end markets that Dana serves. For end markets Allison Transmission serves, Dana and Allison have signed a letter of intent to explore a strategic alliance through which Dana would exclusively manufacture transmission components with NuVinci CVP technology for Allison. Full-scale production of transmissions with NuVinci-equipped components in Dana's off-highway markets is expected within the next three to five years, while implementation in passenger and commercial vehicles is anticipated before the end of this decade.
Inteva expands in India
Inteva Products recently opened a new plant in India for manufacture of door latches, window regulators, and associated motors. The 72,000-ft² (6700-m²) facility in Pune's Chakan industrial area was designed for future expansion to about 100,000 ft² (9300 m²). Inteva India has complete execution and operational capabilities with full quality-assurance testing for both closure systems and motors and electronic product lines. The plant is designed to accommodate organic growth and has the potential for future expansion into the company's other product lines (interior systems and roof systems). In addition to the Pune Operation, Inteva has a technical center in Bangalore employing approximately 150 engineers and serving global and India business.
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Pune plant operations includes manufacturing lines for door latches, window regulators, and motors, with in-process testing capabilities.
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