Concurrent engineering and DFMA approaches on the development of automotive panels and doors

• Autorzy: Krumenauer F. Z. , Matayoshi C. T. , da Silva I. B. , Filho M. S. , Batalha G. F.
• Języki publikacji: EN

Abstrakty

EN

Purpose: The automotive industry, in countries such as Brazil, China and India, in contrast to the North American and European markets, is in full expansion. Due to the huge competition in the globalized automotive market, such countries face a challenge to continue this expansion. Especially important in order to win this battle, will be their capacities to release new products in the market faster than their competitors and with more cost efficiency, making an appropriate use of tools such as total quality management, concurrent engineering and increasing the use of innovative concepts in production and logistics [1,2]. Design/methodology/approach: According with the expose above, the aim of this work was to develop DFMA tools for an industrial real case. There several tools that could be included in the Design for Excellence (DFX) methodologies. Initially, two of those can be outstand here: Design For Manufacturing (DFM) and Design For Asse. Findings: In terms of the press shop facilities of the plant the main results, were: layout optimization, press line automation feasibility, reduced setup and increased productivity, improved racks logistic, reduced overhead, reduced stamped part scraps and resources with mechanical presses selling. In terms of the planning activities, the main results were: reduce time to market, reduce press shop machinery and die stamping investments and reduce indirect cost. Practical implications: The main proposal of concurrent engineering is to shorten a product development time through a simultaneous time implementation of the several stages of the engineering activity in parallel and under a concurrent mode offering all information required by all elements of the product life cycle. Originality/value: This paper reviews fundamental concepts in concurrent engineering and DFX aiming to discuss criteria of assembly and manufacturability regarding the development of automotive panels and doors. A more detailed presentation of the Finite Element Analysis (FEA) and Computer Aided Design (CAD) results obtained during the practical industrial case of auto body panel development are not presented here due to data confidentiality and page limitation.

Słowa kluczowe

EN

concurrent engineering; sheet metal forming; BIW; DFMA; DFX; DFR; DFE

PL

projektowanie współbieżne; tłoczenie blachy

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2008
• Tom: Vol. 31, nr 2
• Strony: 690--698
• Opis fizyczny: Bibliogr. 20 poz., wykr.

Twórcy

autor

Krumenauer F. Z.

autor

Matayoshi C. T.

autor

da Silva I. B.

autor

Filho M. S.

autor

Batalha G. F.

• General Motors do Brasil Ltda-Automotive Body Assembly Plant, Sao Caetano do Sul, SP, Brazil,

Bibliografia

• [1] R. F. Z. Chiusoli, J. C. de Toledo, Engenharia simultanea: estudo de casos na industria brasileira de autopecas, Proceedings of the Congresso Brasileiro de Gestao de Desenvolvimento de Produto, Ed. UFSCar, Brazil, 2000, 10-19.
• [2] J. R. S. T. Motta, Melhoria da qualidade do automóvel brasileiro, Brasília, Câmara dos Deputados, 2001, 5 (Nota técnica, 104036).
• [3] G. F. Batalha, R. C. Schwarzwald, G. L. Damoulis, New trends in computer simulation as integrated tool for automotive component development, Proceedings of the International Conference „Numerical Methods in Industrial Forming Processes” NUMIFORM, Columbus, 2004, 21032-21037.
• [4] G. L. Damoulis, G. F. Batalha, Desenvolvimento de processo de conformacao de chapas metálicas usando simulacao computacional como ferramenta integrada no desenvolvimento de carrocerias automotives, Engineering and Science Journal 13 (2004) 33-39 (http://www.cieng.ufu.br/REVISTA_COBEF.PDF).
• [5] C. T. Matayoshi, Concurrent Engineering-Study of the Process Requirements and Life Cycle Influence in the Development of Automobile Stamped Parts, Master Thesis, EPUSP, Sao Paulo, 2005 (Full text available: http://www.automotivapoliusp. org.br/mest/banc/pdf/matayoshi_cesar.pdf).
• [6] F. Z. Krumenauer, G. F. Batalha, Concurrent Engineer and Design for Manufacturing and Assembly Automotive Doors Projects, Boletim Técnico EPUSP-BT/PME/0803 (2008) 15, (http://www.mecanica-poliusp.org.br/05pesq/cont/pdf/803.pdf and full text of the professional master thesis available on http://www.automotiva-poliusp.org.br/mest/banc/pdf/krumenauer_fabio.pdf).
• [7] G. Boothroyd, P. Dewhurst, W. Knight, Product Design for Manufacture and Assembly, Marcel Decker Incorporation, New York, 1, 2002, 1-29.
• [8] G. L. Damoulis, E. Gomes, G. F. Batalha, Combined finite element: forming limit diagram methodology for the development of automotive body stamped parts, International Journal of Mechatronics and Manufacturing Systems 1/2-3 (2008) 264-281.
• [9] J. R. Hartley, Engenharia Simultânea: um método para reduzir prazos, melhorar a qualidade e reduzir custos. First Edition, Bookman, Porto Alegre, 1998, 266.
• [10] T. C. Chang, R. Wysk, H. P. Wang, Computer-Aided Manufacturing, ch. 14-Concurrent Engineering, Prentice Hall International Series in Industrial and Systems Engineering, Prentice Hall, Second Edition, 1998, 589-616.
• [11] M. Geiger, Towards Clean Forming Techniques, Annals of the CIRP 44/2 (1995) 581-588.
• [12] R. Kopp, A. Schmitz, Plastic working in Germany and related environmental issues, Journal of Materials Processing Technology 59 (1996) 186-198.
• [13] S. Schmidt, Preventive Optimisation of Costs and Quality for the Total Life Cycle-design for manufacture, assembly, service, environment (DFMA), Proceedings of the Conference and Exposition „Total Life Cycle”, Graz, 1998, 1-9.
• [14] T. C. Kuo, S. H. Huang, H. C. Zhang, Design for manufacture and design for 'X': concepts applications and perspectives, Computer and Industrial Engineering 41 (2001) 1-20.
• [15] P. J. M. Figueiredo, S. J. Jacovelli, Projeto para montagem de máquinas-ferramentas. Máquinas e Metais, Aranda Editora XLII/488 (2006) 156-197.
• [16] K. Hockerts, S. Adda, H. Teulon, D. Dowdell, N. Kirkpatrick, S. Aumonier, Beyond Life Cycle Assessment, an Integrative Design for Environment Approach for the Automotive Industry, SAE Technical Paper Series (1998) 1-7.
• [17] S. Addouche, Contribuition a une demarche de conception optimisée des processus de désassemblage, 203 f. These (Grade de docteur de l'Université de Franche-Comte), 1, 2003, 1-23.
• [18] A. Desai, A. Mital, Evaluation of disassemblability to enable design for disassembly in mass production, International Journal of Industrial Ergonomics 32 (2003) 1-17.
• [19] R. Koehr, ULSAC-Lightweight steel auto closures, Proceedings of the SAE 2001 World Congress, Detroit, 2001, SAE Paper 2001-01-0076.
• [20] G. T. Nakamura, M. T. Yokota, G. F. Batalha, Linha de desmontagem de chapas de aço para reciclagem. Monography PMR-EPUSP, Sao Paulo, 2002, 72.