Abstract: The paper presents the influence of non-metallic inclusions on the multi-stage forging process and the mechanical properties of the dodecagon socket bolt used in the automotive industry. The detected metallurgical defect was so large that it directly influenced the mechanical properties of the bolt and resulted in failure to meet the requirements of the mechanical property class. In order to assess the defect, an X-ray examination and metallographic examination of the defective bolt were performed, showing exogenous non-metallic inclusion. The size of the defect on the cross section was 0.531 mm in width and 1.523 mm in length; the defect was continuous along the entire axis of the bolt. In analysis, a finite element method (FEM) simulation of the multi-stage forging process was designed, taking into account a non-metallic inclusion parallel to the sample axis, reflecting the studied case. The process of defect propagation due to material upset in the head area was analyzed. The final forging stage in shaping the dodecagonal socket and filling the flange area was particularly studied. The effect of the defect was observed to significantly reduce the effective cross-section as a result of the expansion of the defect perpendicular to the axis of the bolt. The mechanical properties of products with and without the defect were analyzed. In the first step, the hardness test confirmed that the required value for the mechanical class 8.8 of both bolt types was obtained. In the second step, the bolts were subjected to a static tensile test. The bolts without the defect gave a positive result, while all 10 bolts with the defect gave a negative result, achieving a tensile strength below the requirements. Tensile strength tests were confirmed by metallographic tests and FEM simulation with perpendicular inclusion spread in the area of the head. The bolts were damaged directly under the bolt head, which is inconsistent with the requirements of ISO 898-1. It has been shown that non-metallic inclusions with orientation in accordance with the axis of the bolt can directly cause loss of functionality and these defects should be detected even before assembling in the machine element.
Abstract: The purpose of the paper is to redefine the levels of structure of corporate, business and functional strategies that were established over the past several decades, to a conceptual model, consisting of corporate, business and operations strategies, that are reinforced by functional strategies. We will propose a conceptual framework of different perspectives in the role of strategic operations as a separate strategic place and reposition the remaining functional strategies as supporting tools, existing at all three levels. The proposed model is called ‘the strategic engine’, since the mutual relationships of its ingredients are identical with main elements and working principle of the internal combustion engine. Based on theoretical essence, related to every strategic level, we will prove that the strategic engine model is useful for managers seeking to safeguard the competitive advantage of their companies. Each strategy level is researched through its basic elements. At the corporate level we examine the scope of firm’s product, the vertical and geographical coverage. At the business level, the point of interest is limited to the SWOT analysis’ basic elements. While at operations level, the key research issue relates to the scope of the following performance indicators: cost, quality, speed, flexibility and dependability. In this relationship, the paper provides a different view for the role of operations strategy within the overall strategy concept. We will prove that the theoretical essence of operations goes far beyond the scope of traditionally accepted business functions. Exploring the applications of Resource-based theory and Market-based theory within the strategic levels framework, we will prove that there is a logical consequence of the theoretical impact in corporate, business and operations strategy – at every strategic level, the validity of one theory is substituted to the level of the other. Practical application of the conceptual model is tested in automotive industry. Actually, the proposed theoretical concept is inspired by a leading global automotive group – Inchcape PLC, listed on the London Stock Exchange, and constituent of the FTSE 250 Index.
Abstract: Any industrial company needs to determine the amount of variation that exists within its measurement process and guarantee the reliability of their data, studying the performance of their measurement system, in terms of linearity, bias, repeatability and reproducibility and stability. This issue is critical for automotive industry suppliers, who are required to be certified by the 16949:2016 standard (replaces the ISO/TS 16949) of International Automotive Task Force, defining the requirements of a quality management system for companies in the automotive industry. Measurement System Analysis (MSA) is one of the mandatory tools. Frequently, the measurement system in companies is not connected to the equipment and do not incorporate the methods proposed by the Automotive Industry Action Group (AIAG). To address these constraints, an R&D project is in progress, whose objective is to develop a web and cloud-based MSA tool. This MSA tool incorporates Industry 4.0 concepts, such as, Internet of Things (IoT) protocols to assure the connection with the measuring equipment, cloud computing, artificial intelligence, statistical tools, and advanced mathematical algorithms. This paper presents the preliminary findings of the project. The web and cloud-based MSA tool is innovative because it implements all statistical tests proposed in the MSA-4 reference manual from AIAG as well as other emerging methods and techniques. As it is integrated with the measuring devices, it reduces the manual input of data and therefore the errors. The tool ensures traceability of all performed tests and can be used in quality laboratories and in the production lines. Besides, it monitors MSAs over time, allowing both the analysis of deviations from the variation of the measurements performed and the management of measurement equipment and calibrations. To develop the MSA tool a ten-step approach was implemented. Firstly, it was performed a benchmarking analysis of the current competitors and commercial solutions linked to MSA, concerning Industry 4.0 paradigm. Next, an analysis of the size of the target market for the MSA tool was done. Afterwards, data flow and traceability requirements were analysed in order to implement an IoT data network that interconnects with the equipment, preferably via wireless. The MSA web solution was designed under UI/UX principles and an API in python language was developed to perform the algorithms and the statistical analysis. Continuous validation of the tool by companies is being performed to assure real time management of the ‘big data’. The main results of this R&D project are: MSA Tool, web and cloud-based; Python API; New Algorithms to the market; and Style Guide of UI/UX of the tool. The MSA tool proposed adds value to the state of the art as it ensures an effective response to the new challenges of measurement systems, which are increasingly critical in production processes. Although the automotive industry has triggered the development of this innovative MSA tool, other industries would also benefit from it. Currently, companies from molds and plastics, chemical and food industry are already validating it.
Abstract: Friction stir welding is a modern and an environmentally friendly solid state joining process used to joint relatively lighter family of materials. Recently, friction stir spot welding has been used instead of resistance spot welding which has received considerable attention from the automotive industry. It is environmentally friendly process that eliminated heat and pollution. In this research, friction stir spot welding has been used to study the possibility to weld AA1100 aluminum alloy sheet with 3 mm thickness by overlapping the edges of sheet as lap joint. The process was done using a drilling machine instead of milling machine. Different tool rotational speeds of 760, 1065, 1445, and 2000 RPM have been applied with manual and automatic compression to study their effect on the quality of welded joints. Heat generation, pressure applied, and depth of tool penetration have been measured during the welding process. The result shows that there is a possibility to weld AA1100 sheets; however, there is some surface defect that happened due to insufficient condition of welding. Moreover, the relationship between rotational speed, pressure, heat generation and tool depth penetration was created.
Abstract: The demand for an increasing diversification of the product spectrum associated with the current huge customization desire and subsequently the decreasing unit quantities of each production lot is gaining more and more importance within a great variety of industrial branches, e.g. automotive industry. Nevertheless, traditional product development and production processes (molding, extrusion) are already reaching their limits or fail to address these trends of a flexible and digitized production in view of a product variability up to lot size one. Thus, upcoming innovative production concepts like the additive manufacturing technology basically create new opportunities with regard to extensive potentials in product development (constructive optimization) and manufacturing (economic individualization), but mostly suffer from insufficient strength regarding structural components. Therefore, this contribution presents an innovative technological and procedural conception of a hybrid additive manufacturing process (fiber-reinforced sandwich structures based on selective laser sintering technology) to overcome these current structural weaknesses, and consequently support the design of complex lightweight components.
Abstract: Nanotechnology in pristine sense refers to building of
structures at atomic and molecular scale. Meticulously
nanotechnology encompasses the nanomaterials with at least one
dimension size ranging from 1 to 100 nanometres. Unlike the literal
meaning of its name, nanotechnology is a massive concept beyond
imagination. This paper predominantly deals with relevance of
nanotechnology in automotive industries. New generation of
automotives looks at nanotechnology as an emerging trend of
manufacturing revolution. Intricate shapes can be made out of fairly
inexpensive raw materials instead of conventional fabrication
process. Though the current era have enough technology to face
competition, nanotechnology can give futuristic implications to pick
up the modern pace. Nanotechnology intends to bridge the gap
between automotives with superior technical performance and their
cost fluctuation. Preliminarily, it is an area of great scientific interest
and a major shaper of many new technologies. Nanotechnology can
be an ideal building block for automotive industries, under constant
evolution offering a very wide scope of activity. It possesses huge
potential and is still in the embryonic form of research and
development.
Abstract: Lightweight design represents an important key to
successful implementation of energy-saving, fuel-efficient and
environmentally friendly means of transport in the aerospace and
automotive industry. In this context the use of carbon fibre reinforced
plastics (CFRP) which are distinguished by their outstanding
mechanical properties at relatively low weight, promise significant
improvements. Due to the reduction of the total mass, with the
resulting lowered fuel or energy consumption and CO2 emissions
during the operational phase, commercial aircraft will increasingly be
made of CFRP. An auspicious technology for the efficient and
economic production of high performance thermoset composites and
hybrid structures for future lightweight applications is the
combination of carbon fibre sheet moulding compound, tailored
continuous carbon fibre reinforcements and metallic components in a
one-shot pressing and curing process. This paper deals with a hybrid
composite technology for aerospace industries, which was developed
with the help of a special innovation and development system.
Abstract: The use of permanent magnets (PM) is increasing in
permanent magnet synchronous machines (PMSM) to fulfill the
requirements of high efficiency machines in modern industry. PMSM
are widely used in industrial applications, wind power plants and the
automotive industry. Since PMSM are used in different
environmental conditions, the long-term effect of NdFeB-based
magnets at high temperatures and their corrosion behavior have to be
studied due to the irreversible loss of magnetic properties.
In this paper, the effect of magnetic properties due to corrosion
and increasing temperature in a climatic chamber has been presented.
The magnetic moment and magnetic field of the magnets were
studied experimentally.
Abstract: The purposes of this research were to study concepts
and strategies of human resource development in the automotive
manufacturers and to articulate the proposals against the government
about the human resource development for automotive industry. In
the present study, qualitative study was an in-depth interview in
which the qualitative data were collected from the executive or the
executive of human resource division from five automotive
companies - Toyota Motor (Thailand) Co., Ltd., Nissan Motor
(Thailand) Co., Ltd., Mitsubishi Motors (Thailand) Co., Ltd., Honda
Automobile (Thailand) Co., Ltd., and Suzuki Motor (Thailand) Co.,
Ltd. Qualitative data analysis was performed by using inter-coder
agreement technique. The research findings were as follows:
The external factors included the current conditions of the
automotive industry, government’s policy related to the automotive
industry, technology, labor market and human resource development
systems of the country. The internal factors included management,
productive management, organizational strategies, leadership,
organizational culture and philosophy of human resource
development. These factors were affected to the different concept of
human resources development -the traditional human resource
development and the strategies of human resource development. The
organization focuses on human resources as intellectual capital and
uses the strategies of human resource development in all
development processes. The strategies of human resource
development will enhance the ability of human resources in the
organization and the country.
Abstract: Al-Si-Mg-Ni(-Cu) alloys are widely used in the automotive industry. They have the advantage of low weight associated with low coefficient of thermal expansion and excellent mechanical properties – mainly at high temperatures. The corrosion resistance of these alloys in coastal area, particularly sea water, however is not yet known. In this investigation, electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization have been used to evaluate the corrosion resistance of Al-6Si-0.5Mg-2Ni (-2Cu) alloys in simulated sea water environments. The potentiodynamic polarization curves reveal that 2 wt% Cu content alloy (Alloy-2) is more prone to corrosion than the Cu free alloy (Alloy-1). But the EIS test results showed that corrosion resistance or charge transfer resistance (Rct) increases with the addition of Cu. Due to addition of Cu and thermal treatment, the magnitude of open circuit potential (OCP), corrosion potential (Ecorr) and pitting corrosion potential (Epit) of Al-6Si-0.5Mg-2Ni alloy in NaCl solution were shifted to the more noble direction.
Abstract: Simple design of a rotary valve system is capable of controlling intake and exhaust gases, which will eliminate the need of known complex mechanisms. The cost of material and production, maintenance, and noise level of the system can be further reduced. The new mechanism enables the elimination of the overlapping of valves work that reduces gas leakage. This paper examines theoretically the gas flow through the holes of a rotary valve design in a small engine. Preliminary results show that the new gas flow has many positive differences than a conventional poppet-valve system. New dependencies on the gas speed enable the finding of better solutions for the geometry of a rotary valve system that will result in a higher efficiency of an internal-combustion engine of the automotive industry.
Abstract: The objective of this study is to determine the thermal comfort among worker at Malaysian automotive industry. One critical manual assembly workstation had been chosen as a subject for the study. The human subjects for the study constitute operators at Body Assembly Station of the factory. The environment examined was the Relative Humidity (%), Airflow (m/s), Air Temperature (°C) and Radiant Temperature (°C) of the surrounding workstation area. The environmental factors were measured using Babuc apparatus, which is capable to measure simultaneously those mentioned environmental factors. The time series data of fluctuating level of factors were plotted to identify the significant changes of factors. Then thermal comfort of the workers were assessed by using ISO Standard 7730 Thermal sensation scale by using Predicted Mean Vote (PMV). Further Predicted percentage dissatisfied (PPD) is used to estimate the thermal comfort satisfaction of the occupant. Finally the PPD versus PMV were plotted to present the thermal comfort scenario of workers involved in related workstation. The result of PMV at the related industry is between 1.8 and 2.3, where PPD at that building is between 60% to 84%. The survey result indicated that the temperature more influenced comfort to the occupants
Abstract: Although automotive industry has brought different beneficiaries to human life, it is being pointed out as one of the major cause of global air pollution which resulted in climate change, smog, green house gases (GHGs), and human diseases by many reasons. Since auto industry is one of the largest consumers of fossil fuels, the realization of green innovations is becoming a crucial choice to meet the challenges towards sustainable development. Recently, many auto manufacturers have embarked on green technology initiatives to gain a competitive advantage in the global market; however, innovative manufacturing systems and technologies can enhance operational performance only if the human resource management is in place to elicit the motivation of the employees and develop their organizational expertise. No organization can perform at peak levels unless each employee is committed to the company goals and works as an effective team member. Strategic human resource practices are the primary means by which firms can shape the skills, attitudes, and behavior of individuals to align with the business strategic objectives. This study investigates on the comprehensive approach of multiple advanced technology innovations and human resource management at Toyota Motor Corporation as the market leader of full hybrid technology in the automotive industry. Then, HRM framework of the company is described and three sets of human resource practices that support the innovation-oriented HR system, presented. Finally, a conceptual framework for innovativeness in green technology in automotive industry by applying a deliberate strategic HR management system and knowledge management with the intervening factors of organizational culture, knowledge application and knowledge sharing is proposed.
Abstract: This paper addresses integration issues in supply
chain, and tries to investigate how different aspects of integration are
linked with some product features. Integration in this study is
interpreted as "internal", "upstream" (supply), and "downstream"
(demand). Two features of product innovative and quality are
considered. To examine the relationships between supply chain
integrations – as mentioned above, and product features, this research
follows the survey method in automotive industry.The results imply
that supply chain upstream integration has a higher impact on product
quality, comparing to internal and supply chain downstream
integrations. It is also found that the influence of supply chain
downstream integration on product innovation is greater than other
variables. In brief, this study mainly tackles the importance of
specific level of supply chain integrations and its effects on two
product features.
Abstract: The right information at the right time influences the
enterprise and technical success. Sharing knowledge among members
of a big organization may be a complex activity. And as long as the
knowledge is not shared, can not be exploited by the organization.
There are some mechanisms which can originate knowledge sharing.
It is intended, in this paper, to trigger these mechanisms by using
semantic nets. Moreover, the intersection and overlapping of terms
and sub-terms, as well as their relationships will be described through
the mereology science for the whole knowledge sharing system. It is
proposed a knowledge system to supply to operators with the right
information about a specific process and possible risks, e.g. at the
assembly process, at the right time in an automated manufacturing
environment, such as at the automotive industry.