HARNESSING THE POWER OF INNOVATION FOR NEXT GENERATION LIGHTWEIGHTING TECHNOLOGIES. Lyle Otremba Innovation and Advanced Product Strategy

Transcription

1 HARNESSING THE POWER OF INNOVATION FOR NEXT GENERATION LIGHTWEIGHTING TECHNOLOGIES Lyle Otremba Innovation and Advanced Product Strategy

2 Everything that can be invented, has been invented. Charles H. Duell Commissioner, U.S. Office of Patents 1899 Put two things together that have never been put together before, and some schmuck will buy it George Carlin 2

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4 Innovation Process Based on Customer Needs Culture Process Organization 4

5 Project Evaluation Scorecard Helps Identify and Prioritize Projects Ideas are scored to determine importance / viability Above 60 achieves assignment GTC determines where 5

6 Global i 3 Portal Generates Projects 323 Total i 3 Submissions 15 Active i 3 Projects 9 High-Active i 3 Projects Innovation team focused here 59 Global Innovation Ideas 204 Selected Ideas Idea Inventory 7 Innovation Projects have come through the i³ process 6

7 Global Trends Three Key Drivers ( MEGATRENDS ) Will Impact the Industry for the Next Ten Years Global Platforms Emissions / Fuel Economy Legislation Globally Autonomous and Connected Vehicles Produced in two or more regions Common global architectures: fewer platforms, more variants Well positioned suppliers gain market share Regional suppliers left behind Requires weight reduction Adherence to green materials & processes Introduces alternative powertrains Public slow to adopt Creates need for quieter interiors Will affect vehicle ownership model and durability requirements Technology is ahead of policy 7

8 Automotive OEMs: Challenges Ahead Mass is the single, largest driver for emissions 2015 Target 2020 Target Source: European Environment Agency Data

9 Engine Mount Lightweighting Solutions Thermoplastic PA 50% Short or Long Fiber Solutions already in serial production Hybrid Metal/thermoplastic Limited weight saving Thermoset Composite Long cycle time Difficult Rubber to Metal bonding Several projects on-going Thermoplastic Composite : DYNAFIB Results in Strongest Part Lightest Weight Option 9

10 Project : DYNAFIB Project Overview The Project: Thermoplastic Composites Reinforced with Continuous Fibers A strategic effort to develop a process enabled composite part design, targeting a 50% weight reduction versus metal based AVS solutions DYNAFIB Performance Reduce Weight and Maintain or Gain Strength to Parts 10

11 Project : DYNAFIB Development Process MAY 2014 JUNE 2016 STEP 1 STEP 2 STEP 3 STEP 4 Material Selection June Process Parameter Definition June Mar 2015 FEA Modeling Nov Sept 2015 Process and Product Validation June June 2016 G1 G3 11

12 Project : DYNAFIB Mass Production Process Reinforcement Manufacturing Thermoplastic Overmolding 12

13 Project : DYNAFIB Applications Torque Rod Application 50% Weight Savings Engine Mount Application 35% Weight Savings Structural Part Application 40-50% weight savings Significant Weight Reduction Now Possible in Key Structural Components 13

14 Fortrex : Transforming the Future of Weatherseal Systems Fortrex is a next generation Lightweight elastomer that delivers superior sealing, weatherability, NVH, and gloss performance. BENEFITS 30%+ Mass Reduction Versus Dense EPDM 10%+ Mass Reduction Versus Dense TPV Superior Compression Set Characteristics High Elasticity Performance Non-Conductive, Non-Blooming, Non-Fogging Exceptional Weathering Performance Improved Scratch Performance No VOC's (Volatile Organic Compound), No Nitrosamine Broad Color Matching Capabilities Improved NVH and acoustic Performance Over Time TARGET APPLICATIONS Frame Under Glass- Glass Run Systems Channel Mounted- Glass Run Systems Inner Waist Belt Outer Waist Belt Below Waist Extrusion 14

15 Bringing New Ideas to Customers Creating New Products to Make Cooper Standard Stronger Fortrex Sealing Revolutionizes sealing industry with new material science Reduces weight, improves performance, and offers appearance options ArmorHose, ArmorHose II, and ArmorHose III Eliminates requirement for protective sleeves on hoses Reduces weight and labor costs Provides a recyclable and extended-life option MagAlloy Coating Improves corrosion performance and product life utilizing proprietary technology Exclusive to Ultra Nyclad and UltraPro Coat Products Gen III Quick Connect Improves connections with sensor capability Quick connector with integrated sensor for pressure and temperature measurement of fuel and vapor Simplifies systems; reduces mass and complexity 15