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As a part of the Global Green Engineering Initiative at the US-Japan Center for Technology Management at Vanderbilt University, an Internet-based Environmentally Conscious Decision Support tool (EcoDS) has been developed for life-cycle management. EcoDS is used to compare different alternatives for manufacturing processes or product designs with regards to cost and residual risk, and includes a user-defined value system. This tool uses a vertical streamlining approach applied prior to the data input, to reduce data collection efforts and to speed the life-cycle assessment process. The output is condensed into a single summary matrix. It has been deemed useful to create a version of EcoDS designed specifically for the automotive industry (AutoEcoDS). This program will involve multiple modules each related to a different aspect of the manufacture of automobiles and automotive products.

Saturn Strategy: To manage environmental issues throughout the product lifecycle…from design through post-consumer disposal. In 1993 Saturn began a focused effort to understand the strengths and weaknesses of a U.S. based closed-loop captive recycling program. This study conducted during a 12-month period (February 1993-February 1994) with 17 participating Saturn Retailers nationwide proved that a captive closed-loop process was feasible. During that period front and rear vehicle fascias were returned via the Saturn transportation system to Spring Hill, Tennessee, where they were ground and reused in vehicle wheelliners of the Saturn vehicle. That program was expanded to all Saturn Retailers in 1994 and continues with a high degree of success today. With the infrastructure to support this effort two other plastic commodities await introduction in the system.

This paper provides a qualitative overview of the environmental aspects of the Lost Foam casting process. The paper divides the subject into the following major environmental media: solid waste, air emissions, wastewater, and energy consumption. Within each of these major areas, the significant materials used in the process and the significant wastes or emissions generated are discussed, along with disposal methods and control strategies. The paper will demonstrate that the Lost Foam casting is an environmentally friendlier process than other competitive casting processes. Many of the direct materials used in the process and much of the solid waste generated can be recycled. The air emissions occur in a few localized areas and can be easily captured and controlled. The majority of the wastewater generated is relatively clean and easily treated. Finally, the energy consumption of the process is briefly discussed.

Training is an essential element for any manufacturer to successfully implement Lean Manufacturing (LM). The University of Tennessee has developed training modules for small to medium sized manufacturers who typically have a more difficult time allocating resources to training. The methodology for developing the LM modules and the results of presenting these modules in pilot sessions and in training sessions are presented.

A program for defining and tracking Quality, Cost, Delivery and Safety performance. In any manufacturing environment, understanding and controlling the shop floor process is vital. Effective shop floor management begins with understanding your current process and establishing clear objectives of what you want to accomplish. This presentation will outline the steps necessary to implement an effective shop floor management program. It is based on the shop floor management activities established by the Stamping Plant at Nissan Motor Manufacturing Corporation USA. Included in this presentation will be an overview of Shop Floor Management at NMMC with a focus on practices and procedures for effective process control, problem response and countermeasure and visual/policy management.

Shifts in the automotive marketplace from price based competition to value added competition (such as quality, short delivery lead time and product variety) have increased the need for developing effective final assembly sequencing methods. Further, recent trends such as component modularity, and high frequency just-in-time deliveries tightened the operational linkages in the supply chain between the assembly plants and suppliers. These factors contribute to the need for not only developing effective assembly schedules, but also developing methods to eliminate the deviations from the planned sequence. In this paper, we identify and discuss major issues (such as quality, load smoothing in the final assembly line, leveling material requirements from suppliers, and operational economies resulting from batching operations) to be considered in developing final assembly schedules.

A method of reducing cumulative trauma injuries based on ergonomic job rotation In today's growing global market many companies are implementing activities to improve productivity and employee performance in order to produce more saleable value per employee. Because of increased performance many of these improvement activities have led to higher injury rates based on repetitive cumulative trauma. This session will deal with understanding the role and effects of ergonomics on the shop floor. It will demonstrate how to analyze each job based on ergonomic effects, categorize those jobs and develop a job rotation schedule based on simple ergonomics, which will allow operators recovery time from cumulative repetitive motion.

After a brief introduction to thermal infrared imaging, this paper will discuss thermal imaging directly related to applications within the automotive industry. The applications will be those that are known today and future application of infrared technology.

With the introduction of the New Beetle, Volkswagen is offering the next generation of the 1.9l TDI engine. Several evolutionary changes have been made to the TDI concept to further improve its emissions, efficiency and performance. Emissions performance is improved with increased fuel injection pressure, optimized fuel injectors, calibration modifications, EGR cooling and reduced crevice volume in the combustion chamber. Efficiency is improved with new oil pump, vacuum pump and water pump drive systems and the elimination of an auxiliary driveshaft. Performance and efficiency is improved with the addition of a variable geometry turbocharger, which increases torque at lower engine speeds while preserving performance at higher engine speeds. This paper describes the many enhancements found in this latest generation TDI and gives a brief lookout to the future trends in diesel engine development such as a high pressure injection system with unit injectors.

Heavy-duty vehicles account for approximately 30 percent of the oxides of nitrogen (NOx) and 65 percent of the particulate matter (PM) emissions from the entire California on-road fleet, despite the fact that these vehicles comprise only 2 percent of the same. To meet legislative mandates to reduce excess smoke emissions from in-use heavy-duty diesel-powered vehicles, the Air Resources Board (ARB or Board) adopted, in December 1997, amendments to the regulations governing the operation and enforcement of the Heavy-Duty Vehicle Inspection Program (HDVIP or the “roadside” program) and the Periodic Smoke Inspection Program (PSIP or the “fleet” program). The initial roadside program was adopted in November 1990 in response to Senate Bill (SB) 1997 (stat. 1988, ch. 1544, Presley), and enforced from 1991 to 1993. It was suspended in October 1993, when the Board redirected staff to investigate reformulated fuels issues.

The heat treatment of steel parts is an essential step in the manufacturing of high-performance components for a variety of commercial and military products. Distortion in the size and shape of parts resulting from the heat treatment process is a pervasive manufacturing problem that causes higher finishing costs, excessive scrap and rework, long delivery times, and negative environmental impact. To date, techniques that have been developed to reduce or eliminate heat treatment distortion are largely based on experience and have been limited to trial and error. This presentation describes the philosophy and results of an ongoing collaborative project to develop a methodology and computer simulation capability to predict ferrous alloy component response (distortion, residual stress, and microstructure) to industrial heat treatment processes for automotive, truck, bearing, and aerospace applications.

The computer-aided-design and analysis of a robust casting process requires the optimization of both mold filling and solidification. A number of commercial casting codes are available for modeling the fluid flow during mold filling and the heat transfer during solidification. The next generation casting process models will build on present capabilities to allow the prediction of microporosity and other defects and microstructure. This paper will discuss the issues involved in the development of next generation casting process models and present results from a computer model for microporosity prediction that is based on first principles, and will take into account alloy composition, alloy microstructure, the initial hydrogen content of the liquid alloy, and the resistance to inter-dendritic fluid flow to feed shrinkage.

Metal Compression Forming (MCF) is a variant of the squeeze casting process, in which molten metal is allowed to solidify under pressure in order to close porosity and form a sound part. However, the MCF process applies pressure on the entire mold face, thereby directing pressure on all regions of the casting and producing a uniformly sound part. The process is capable of producing parts with properties close to those of forgings, while retaining the near net shape, complexity in geometry, and relatively low cost of the casting process. The paper describes the casting process development involved in the production of an aluminum A357 alloy motor mount bracket, including the use of a filling and solidification model to design the gating and determine process parameters. Tensile properties of the component are presented and correlated with those of forged components.

The emphasis automotive manufacturers have placed on lightweight, low-cost components has resulted in a number of custom-engineered materials which have outstanding properties. High temperature polymers and composites, low cost nickel-based alloys, and surface coatings are areas in which material development has lead to parts with improved performance at lower cost. This paper explores the feasibility of employing laser surface processing to provide better performance for two key engine applications, cylinder bores and valve seats. The Laser Induced Surface Improvement (LISI, patent-pending) technique developed at The University of Tennessee Space Institute, is a surface modification technique which can provide high quality surface layers. Example laboratory tests on processed aluminum substrates indicate that hardness and wear-resistance can be substantially improved.

This paper discusses a design of Internet-based remote manufacturing system, which would help a global company to centralize its production, to control and to monitor the operation from the remote sites. In our design, we describe our system in two main categories, which are the design system and the manufacturing system. In the design system, we use the Internet-based client-server architecture to allow multiple clients to design products collaboratively and simultaneously. After the design is finished, it will be sent to the manufacturing system. At this stage, the clients can control and monitor the process from geographically distributed locations via the Internet.

Painting a vehicle's exterior is an energy and emission-intensive process. Molding exterior panels in color has the potential to reduce both environmental burdens and cost. This study compares the material and energy flows for painting exterior panels (one front and one rear fascia) with those for molding the panels in color at the Saturn manufacturing facility. Molding fascias in color requires the addition of 62,700 kg of color pellets to the injection molding process, but eliminates several painting steps. These changes would result in reducing paint consumption by 500,000 kg/yr, energy consumption by 133 million MJ and volatile organic compound (VOC) emissions by 150,000 kg/yr.

Selecting the proper work group to resolve engineering issues is an unconventional process used by some Saturn engineering teams that give them a definite competitive edge. This process and training will not only improve performance but generate greater awareness between team members of various issues being worked by the group. Conventional Linear work groups are two dimensional and each cell (engineering resource) has a specific function. The cells will only perform the functions assigned by management. A Cluster work group is three dimensional and each cell shares the responsibility of the other. They are able to assume the rolls of each other through team issue awareness and “team imposed” training. This multi-functional team is not only able to close issues faster when they arise, but also in many cases, to stop a potential issue before it even hits the manufacturing facility.

A joint project was undertaken with an auto industry group, the Environmental Research Consortium (ERC), J-TEC Associates, Inc., and the Oak Ridge National Laboratory (ORNL) to develop an economical, real-time exhaust gas flow measurement system. A commercially available flowmeter did not exist for vehicle applications, even after 40 years of various attempts. The flowmeter that was developed, using vortex-shedding measurement principles, has wide rangeability, high accuracy, and environmental compatibility. While near-term benefits of the technology include the capability to certify a vehicle's ability to meet new environmental regulations, the flowmeter can also be used to assist in the development of new engines and enhanced engine performance.

Implementing Lean Manufacturing systems has become a driving force for achieving low cost production in today's manufacturing environments. The goals of lean manufacturing systems include reducing Work In Process (WIP), reducing non-value added production time, and reducing total operating costs to achieve a more agile and flexible production system. However, a low operating cost system that is not capable of meeting customer demand can become very expensive due to lost sales and market share. Simulation modeling can be used to optimize the process while applying lean manufacturing concepts and achieving throughput requirements. Simulation modeling can determine where a process can afford to become lean while monitoring system responses to ensure system requirements are achieved.

The focus of this effort is to illustrate to the decision-makers in the automobile industry the value of Flexible Simulation Modeling (FSM) as a mechanism to implement pervasive simulation modeling. Pervasive simulation implies the use of simulation throughout the organization from design of the product to actual production of the product. This concept is a key to automotive manufacturers reducing their cost of reiterative modification, and destructive testing. Flexible Simulation Models is a term that describes simulation models that is coupled with other software to allow the user to redesign the production process to modify the characteristics of the current production process in a user friendly manner to encourage the use of simulation. FSM has two primary advantages over current static simulation modeling. First, the user is no longer dependent on simulation expertise or a programmer to reprogram the model when changes to the model want to be investigated.