Automotive News - October 6, 2008 - (Page 17) OCTOBER 6, 2008 • 17 TL stretches factory’s flexibility New materials require Honda plant to make drastic changes Ralph Kisiel rkisiel@crain.com MARYSVILLE, Ohio — Acura customers may not notice the weightsaving aluminum hood on the redesigned 2009 Acura TL sedan, but employees at the Marysville Auto Plant sure did. The use of aluminum, hotstamped steel and other new materials for the TL had a huge impact on manufacturing at the Honda of America Manufacturing Inc. plant here. Carmakers are eager to improve fuel economy by changing to lighter weight materials. Honda’s experience shows that switching, say, aluminum for steel is a complicated process requiring lots of planning and time. The Acura redesign was the first use of aluminum on any vehicle produced at Honda’s oldest manufacturing plant in the United States, requiring changes in virtually every major department in the factory. “With the challenges that the team members faced on this, in stamping, welding, paint and assembly — the whole team — it was a huge undertaking,” says Tom Pischel, engineering project leader for the redesigned TL. “By introducing aluminum, it increased our capability, but it also drastically changed the characteristics of how we operate.” Honda would not disclose the investment required to prepare Marysville for the redesigned TL. The front-drive version of the 2009 TL went on sale Sept. 24. The all-wheel-drive model goes on sale in early November. Marysville already was a flexible factory, able to build cars and trucks on the same assembly line. The plant currently assembles the Acura TL and RDX crossover and the Honda Accord car. Changes made for the TL added to that flexibility. Because aluminum replaced steel on the Acura TL’s hood, Honda’s Marysville Auto Plant replaced the destacking robot’s magnets with suction cups. The robot picks up the top sheet and feeds it into the stamping press. Honda adapts to new materials Honda’s Marysville Auto Plant in Ohio is using aluminum and ultrahighstrength steel for the first time in the redesigned 2009 Acura TL. Here are some of the changes at the plant. ■ Installed a custom-made, 6-lane conveyor to prevent deforming the fenders on wraparound taillights as they exit the stamping press ■ Outfitted destacking robot with suction cups rather than magnets, to feed both aluminum and steel sheets into the stamping press ■ Switched phosphate cleansers in the paint shop to prevent flaking of aluminum hood Source: Honda of America Manufacturing TL tango The TL is Acura’s best-selling car. Marysville had to make the necessary manufacturing changes while not disrupting assembly of the RDX and Accord. More than two years ago, the new-model teams at the plant and at Honda R&D Americas Inc. began a tightly choreographed tango. Acura is using aluminum for the new TL’s hood, front suspension subframe, bumper beams, rear suspension knuckles and steering hanger beam. Using an aluminum hood in this fourth-generation TL had an immediate impact on the stamping, welding and painting departments. In stamping, for example, a destacking robot normally uses magnets to pick up the top sheet of steel, called a blank, from a stack of steel sheets, then feeds the sheet into the stamping press. Magnets don’t work on aluminum sheets, so Honda had to retrofit the destacking robot with suction cups so the robot could pick up both the aluminum and steel sheets. Then Honda had to install a second conveyor in stamping. One carries steel scrap and the other aluminum scrap to separate recycling bins. “It’s a swing conveyor, so when we’re not running steel, we swing the aluminum conveyor into place,” says Sam Harpest, Marysville plant manager. “That will catch the scrap. It just gave us more flexibility.” Custom conveyor Honda also installed a custombuilt exit conveyor that moves stamped pieces out of the press. Rather than the typical wide singlebelt conveyor, this new conveyor has six narrow lanes, each of which independently moves laterally and can be raised or lowered. Honda wanted a conveyor that would conform to the shape of the stamping to prevent deforming the piece as it exits the press, Harpest says. The redesigned TL has a wraparound taillight, and the new conveyor prevents stress on the curvature of the taillight’s fender, he says. In the paint shop, Honda had to change the phosphate and filtering system it was using to clean the steel hoods before painting, because that old phosphate caused aluminum hoods to flake. Pischel says the change improved the overall appearance of all models running through the paint shop. The new TL uses five types of high-strength steel, including ultrahigh-strength hot-stamp steel that is heated before it is stamped into shape for the front unit body rails, door sills, B-pillar and side roof rails. Hot-stamp steel, used by Acura for the first time in the 2009 TL, requires changes in how robots make each weld and in how the quality of the welds is tested. Instead of the typical hammer-and-chisel test, the plant introduced a new nondestructive process using an ultrasonic weld checker, Harpest says. “We developed that over about two years prior to actually bringing this model online,” he says. “So we had good, sound confidence that we were still sending a high-quality, high-strength body out.” c Gail Emerine AUTOMOTIVE EVENTS — Erich Gail, 37, to executive vice president. He had been executive vice president of the Midway Group, of Los Angeles, a provider of vehicle acquisition, supply and transportation services. Jeff Emerine, 40, to executive vice president. He had been vice president of operational excellence. Iain Dobson, 45, to senior vice president. He had been vice president of performance technologies. Automotive Events, of Dobson Cleveland, is an events marketing company. FREIGHTLINER CUSTOM CHASSIS CORP. — Scott Lucas, 43, to RV account manager. He had been district sales manager in the southeastern region for Winnebago Industries Inc. Freightliner Custom Chassis, of Gaffney, S.C., supplies chassis Lucas for the recreational vehicle, commercial bus and delivery vehicle industries. It is a subsidiary of Daimler Worldwide. ZAG — Chris Porch, 41, to president and COO. He is a founder of Trilogy Software Inc., of Austin, Texas, and most recently had been CEO of Between Markets Inc., a software provider in Austin that was acquired by Inovis. Zag, of Santa Monica, Calif., is an online service that helps auto dealers sell to so-called affinity groups Porch such as members of credit unions and auto clubs. E-mail personnel news to: autonews@crain.com Or send it to: Deputy Managing Editor Automotive News 1155 Gratiot Ave. Detroit, MI 48207-2997 Please include the employee’s birthdate, new title, most recent title and the full name and location of company.
Table of Contents Feed for the Digital Edition of Automotive News - October 6, 2008 Automotive News - October 6, 2008 Many dealers floored by floorplan limits, costs THE GREAT COLLAPSE September was awful, and 2009 looks ugly GMAC is out of leasing — at least for now Versical, Nussel take new Automotive News posts GM to shut Ohio SUV plant 2 years ahead of plan VW commits to minority purchasing goals in Tenn. Chrysler exec to outline EV strategy at green conference Automakers are high on electrics Dealers give mixed reactions to Chrysler incentive program Chrysler boosts 2009 vehicle prices Lenders move fast to liquidate Heard's stores Mazda Kiyora Toyota, Audi mull tiny cars for U.S. Audi to decide next year on U.S. production Volvo plans diesel hybrid by 2012 Coupelike styling is back in a big way Honda Insight target price: Around $19,000 Mercedes plans U.S. sales of hybrids in S, E, C classes BMW is working on 2 small crossovers VW-Porsche feud risks growth plans Let's get clunkers off the road and spur the economy Europe: Still very different from us It could improve Caddy's image Shouldn't Cadillac try something new? A 4-cylinder is just what Cadillac needs Government's a player in Europe, too The Chevy Cruze should be big news Simple steps would revive industry Ford stops buying nonessential factory supplies Chevy, Mazda execs to speak at congress Automakers find India tough market to conquer Mahle CEO: Most engines will be smaller by 2012 GM begins streamlining purchasing TL stretches factory's flexibility Personnel Study: Dealers gain on independent shops Chrysler offers service contracts on certified vehicles No label Flashes of genius, years of turmoil VW seeks excitement with Routan, CC, Rabbit Sales soft, but Europeans plan to expand lineups 2010 redesign planned for Bentley flagship Alfa beyond Competizione Ferrari: Recession-proof and turning ... green? Maserati: Sporty gets even sportier Uncertainty surrounds Volvo's product plan Rolls-Royce goal: Add customers Panamera: Can Porsche defy skeptics again? Audi longs to join luxury big-leaguers in U.S. BMW plans more variants beyond sedans, wagons Under new owner, Aston Martin back in the race Lagonda's forte: Luxurious sedans that go very fast Couped-up? Lamborghini considers a sedan 250-mph Bugatti boosts the excitement Mercedes returns to the luxury suite Mini follows BMW's lead Smart ambitions, like car, remain small Suppliers cut staff, output to cope with downturn Driver monitoring systems differ High-tech mirrors are poised to make big gains IAC will open first India plant Supplier personnel Engineers call for common electric car standards Land Rover aims to boost the fuel economy of its SUVs Maybach adds open-top 62S Landaulet Saab gets a crossover in 2009; everything else is on hold Jaguar regains its focus on low volume, high end Dealers Economic winds batter Sept. sales Jaguar Land Rover joins group Ford aids minority suppliers CarMax plans 600 job cuts Ruling could ease disputes Feds seek more time for roof strength rule Suzuki seeks floorplan credit partner for dealers Toyota battles Detroit 3 with cheap loans $25 billion: How'd they do that? Peapod: Innovator's little big idea FOR SALE: Heard condos, mansion, jet Is film a flash in the pan? Ford hopes so VW: Next New Beetle will be 'more mature' Renault's U.S. ally of choice? Probably not Chrysler Automotive News - October 6, 2008 Automotive News - October 6, 2008 - GMAC is out of leasing — at least for now (Page 1) Automotive News - October 6, 2008 - GMAC is out of leasing — at least for now (Page 2) Automotive News - October 6, 2008 - Automakers are high on electrics (Page 3) Automotive News - October 6, 2008 - Lenders move fast to liquidate Heard's stores (Page 4) Automotive News - October 6, 2008 - Lenders move fast to liquidate Heard's stores (Page 5) Automotive News - October 6, 2008 - Volvo plans diesel hybrid by 2012 (Page 6) Automotive News - October 6, 2008 - Volvo plans diesel hybrid by 2012 (Page 7) Automotive News - October 6, 2008 - BMW is working on 2 small crossovers (Page 8) Automotive News - October 6, 2008 - BMW is working on 2 small crossovers (Page 9) Automotive News - October 6, 2008 - VW-Porsche feud risks growth plans (Page 10) Automotive News - October 6, 2008 - VW-Porsche feud risks growth plans (Page 11) Automotive News - October 6, 2008 - A 4-cylinder is just what Cadillac needs (Page 12) Automotive News - October 6, 2008 - A 4-cylinder is just what Cadillac needs (Page 13) Automotive News - October 6, 2008 - Simple steps would revive industry (Page 14) Automotive News - October 6, 2008 - Simple steps would revive industry (Page 15) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page 16) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page S-1) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page S-2) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page S-3) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page S-4) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page S-5) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page S-6) Automotive News - October 6, 2008 - Chevy, Mazda execs to speak at congress (Page 16A) Automotive News - October 6, 2008 - Automakers find India tough market to conquer (Page 16B) Automotive News - October 6, 2008 - Automakers find India tough market to conquer (Page 16C) Automotive News - October 6, 2008 - GM begins streamlining purchasing (Page 16D) Automotive News - October 6, 2008 - Personnel (Page 17) Automotive News - October 6, 2008 - Personnel (Page 18) Automotive News - October 6, 2008 - Personnel (Page 19) Automotive News - October 6, 2008 - Chrysler offers service contracts on certified vehicles (Page 20) Automotive News - October 6, 2008 - Flashes of genius, years of turmoil (Page 21) Automotive News - October 6, 2008 - Sales soft, but Europeans plan to expand lineups (Page 22) Automotive News - October 6, 2008 - Alfa beyond Competizione (Page 23) Automotive News - October 6, 2008 - Alfa beyond Competizione (Page 24) Automotive News - October 6, 2008 - Alfa beyond Competizione (Page 25) Automotive News - October 6, 2008 - Rolls-Royce goal: Add customers (Page 26) Automotive News - October 6, 2008 - Rolls-Royce goal: Add customers (Page 27) Automotive News - October 6, 2008 - Panamera: Can Porsche defy skeptics again? (Page 28) Automotive News - October 6, 2008 - Panamera: Can Porsche defy skeptics again? (Page 29) Automotive News - October 6, 2008 - BMW plans more variants beyond sedans, wagons (Page 30) Automotive News - October 6, 2008 - Couped-up? Lamborghini considers a sedan (Page 31) Automotive News - October 6, 2008 - Smart ambitions, like car, remain small (Page 32) Automotive News - October 6, 2008 - Suppliers cut staff, output to cope with downturn (Page 32A) Automotive News - October 6, 2008 - Driver monitoring systems differ (Page 32B) Automotive News - October 6, 2008 - High-tech mirrors are poised to make big gains (Page 32C) Automotive News - October 6, 2008 - Engineers call for common electric car standards (Page 32D) Automotive News - October 6, 2008 - Jaguar regains its focus on low volume, high end (Page 33) Automotive News - October 6, 2008 - Dealers (Page 34) Automotive News - October 6, 2008 - Dealers (Page 35) Automotive News - October 6, 2008 - Dealers (Page 36) Automotive News - October 6, 2008 - Dealers (Page 37) Automotive News - October 6, 2008 - Dealers (Page 38) Automotive News - October 6, 2008 - Dealers (Page 39) Automotive News - October 6, 2008 - Dealers (Page 40) Automotive News - October 6, 2008 - Economic winds batter Sept. sales (Page 41) Automotive News - October 6, 2008 - Economic winds batter Sept. sales (Page 42) Automotive News - October 6, 2008 - Feds seek more time for roof strength rule (Page 43) Automotive News - October 6, 2008 - Toyota battles Detroit 3 with cheap loans (Page 44) Automotive News - October 6, 2008 - Toyota battles Detroit 3 with cheap loans (Page 45) Automotive News - October 6, 2008 - Renault's U.S. ally of choice? Probably not Chrysler (Page 46) Automotive News - October 6, 2008 - Renault's U.S. ally of choice? Probably not Chrysler (Page 47) Automotive News - October 6, 2008 - Renault's U.S. ally of choice? Probably not Chrysler (Page 48)
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