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Light weight parts and chemical management in auto industry
2018.11.05 Satoshi Asada
TOYOTA MOTOR CORPORATION
BSEF Aiea Forum 2018
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1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals
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BSEF Aiea Forum 2018
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14 companies (Passenger, Truck & Bus, Motorcycle )
JAMA member companies BSEF Aiea Forum 2018
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JAMA Committee Organization BSEF Aiea Forum 2018
Board of Directors
Executive Committee
Environment Committee
Factory Environment S/C
Chemical Substance Management S/C
Environment Issues S/C
Recycling & Waste Reduction S/C
・Regulatory trend monitoring ・Vehicle Indoor Air Quality ・Collaborate oversea w/auto sector (GADSL, AI-REACH TF etc.) ・Windows to other industries ・Windows to the JPN Government
1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals
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BSEF Aiea Forum 2018
TOYOTA Environmental Challenge 2050
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6-Challenges
BSEF Aiea Forum 2018
TOYOTA Environmental Challenge 2050
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Engine powered Vehicle
2020 2050 2010
HV PHV
FCV EV
①New vehicle zero CO2 emissions challenge ~▲90% by 2050 compared to 2010~
BSEF Aiea Forum 2018
TOYOTA Environmental Challenge 2050
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② Life Cycle Zero CO2
TOYOTA
BSEF Aiea Forum 2018
1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals
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CO2 trend for vehicle
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Korea EU 67
China 75
Saudi Arabia Australia
Taiwan Brazil
Mexico ① Power train efficiency ② Vehicle aero performance ③ Weight reduction
50% Reduction
Material composition trends
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Steel
Plastics
1968 (1020kg)
1978 (1144kg)
1988 (1300kg)
1996 (1313kg)
2000 (1371kg)
2011 (1471kg) Lexus IS
Mark II
Nonferrous metal Glass
Rubber
Others
Slim up !! philosophy
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・Even now, “Steel” is the major component in automobile So, “Weight reduction” for “Steel” is the main measure. -> Use “High-tensile steel” as much as possible -> Precis control “Steel plate thickness” as parts shape -> Partial optimization for “Material Strength” -> Optimizing “Material joining” methods
・Aluminum(Hood Cover, Chases part, Body part etc.) ・Magnesium(Similar application for Aluminum) ・Plastics(External panel etc.;Recycle, Flame retardant etc.)
1.”Steel” weight reduction as much as possible
2.Utilizing “Light weight materials”
BSEF Aiea Forum 2018
Light weight material trend
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’ 00 ’ 95
’93 SUPRA HOOD ’01 SC430 HOOD, ROOF BACK WINDOW FRAME
’06 LS600h/460 HOOD
’09 SAI HOOD ’11 CT HOOD LIFTGATE
’ 05 ’ 10
’11 Prius α HOOD
’ 90
‘94 RAV4 ROOF
’94 CELICA GT4 HOOD
Steering Wheel Core
Steering Column Jacket
Air Bag Housing
Brake Pedal BRKT
Engine Head Cover
Seat Frame
’ 15
’10 LFA Cabin
’15 MIRAI Stack flame
BSEF Aiea Forum 2018
“Cost”, “Performance”, ”Mass Productivity”, & “Necessity”
Adoption trend C-FRP parts
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FCタンク
BSEF Aiea Forum 2018
CFRP Roof
CFRP Spoiler
CFRP hood
CFRP hood CFRP Roof
CFRP Rear wing
CFRP Backdoor
CFRP Side-door Luggage Roof
Thermoplastic CFRP FC stack flame FC hydrogen tank
Core technology was developed In Lexus LFA & spreading Application.
Fuel Cell vehicle “MIRAI” C-FRP parts
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FC stack flame Hydrogen tank
・Significant weight reduction modify the structure
Worldwide first auto application Thermoplastic CFRP part
MIRAI
Thermoplastic CFRP sheet
BSEF Aiea Forum 2018
C-FRP Hydrogen tank
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■Specification
Pressure 70 MPa
Volume 122.4 L(60.0 L+62.4 L)
H2 storage 5.0 kg
CF-Prepreg
Base
Cylindrical section
Dome section
Boundary section
Plastic Liner (Seals in H2) CF reinforced plastics (Pressure resistance)
GF reinforced plastics (Surface protection)
Dome section
Cylindrical section
Boundary section Liner
Helical winding
High angle Helical winding Hoop winding
BSEF Aiea Forum 2018
Prius-PHV back-door
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-Weight reduction 40% weight reduction compared with Aluminum -Design flexibility Double bubble shape (aerodynamic) Better visibility
C-FRP (C-SMC)
TSOP
38.3°for Prius
40°for Prius-PHV
Lexus LC500 coupe
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V-8 5.0L 477PS 2WD(FR)
Vehicle weight:1.940kg
Lexus LC500 C-FRP parts
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BSEF Aiea Forum 2018
CFRP Door inner
CFRP Roof
CFRP Luggage inner
1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals
20 TOYOTA
BSEF Aiea Forum 2018
Complexity & parts number
21 Body component
Assembly pats : 2,000 – 3,000 / vehicle
Body : 1 Engine : 1 Transmission : 1
Engine component
Transmission component
Component parts: 50,000 and more / vehicle
Complexity parts structure & Number!!
TOYOTA
BSEF Aiea Forum 2018
Automotive supply structure
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BSEF Aiea Forum 2018
Auto-OEM (JAMA, ACEA, USA)
Tier1 Tier1
Auto OEM
Metal (Steel, Nonferrous)
Chemical (Plastics, Paint Adhesive, Fluid Rubber etc.) Electric & Inorganic materials
Tier2 Tier2
Tier3 Tier3 Tier3 Tier3
TierN TierN TierN TierN
Tier2
TierN
Part suppliers (JAPIA, CLEPA etc.)
One Auto-OEM Have 3,000 Tier1 suppliers
Complexity of auto supply chain
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Tier 1
Tier 2
Tier 3
Tier N
Oversea supplier Domestic supplier
(1,500)
(750,000)
(Overseas, law material / article )
TOYOTA
BSEF Aiea Forum 2018
Green Purchasing Guideline
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https://www.toyotaglobal.com/sustainability/environment/management/green/pdf/TOYOTA_Green_Purchasing_Guidelines_2016_en.pdf
IMDS/GADSL collaborations
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Material data (not only materials info.) -Parts info.
-Supplier info.
-Base material info.
-Hazardous substance info.
Data format & rule
GADSL: Global Automotive Declaration Substance List
Data collection system & archive
IMDS : International Material Data System
Substance list
TOYOTA
BSEF Aiea Forum 2018
Outline of IMDS
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What is IMDS? A common platform for collecting/analysing components/material information in the automotive industry.
• An environmental information communication system that 8 European OEMs (Audi, BMW, Daimler Chrysler, Ford, Opel, Porsche, Volkswagen, Volvo) have led development.
• Operated by major OEMs in Asia/US/EU with cost contribution. (6,000,000 euro/year) • A system accessible through an internet. • Suppliers can use the system free of charge. • The system will be available immediately after online registration. • Almost de facto standard in automotive industry for data collection.
TOYOTA
BSEF Aiea Forum 2018
Structure of IMDS
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OEM Tier1 Tier2 Material maker
MDS request for assy
MDS request for component
MDS request for material
MDS data for assy
MDS data for component
MDS data for material
IMDS data flow
TOYOTA
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IMDS data center (former HP)
IMDS adopting auto-OEM
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2000 2002 2004 2006 2008 2010
Auto OEM Membership trend
Participating OEMs : over 30 Participating Suppliers: 168,626 Registered users: 464,725 people (as of April 2018)
TOYOTA
BSEF Aiea Forum 2018
Current status IMDS data
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Approximately 168,626 companies, 69,644,0079data (as of Apr. 2018)
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
IMDS registered data amount IMDS registered companies IMDS registered companies and data amount
IMDS登録企業数 IMDS登録データ数 IMDS registered companies
IMDS registered data amount
TOYOTA
BSEF Aiea Forum 2018
IMDS/GADSL collaborations
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Material data (not only materials info.) -Parts info.
-Supplier info.
-Base material info.
-Hazardous substance info.
Data format & rule
GADSL: Global Automotive Declaration Substance List
Data collection system & archive
IMDS : International Material Data System
Substance list
TOYOTA
BSEF Aiea Forum 2018
Outline of GADSL
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Global Automotive Declarable Substance List
<Remark> ・First GADSL is issued in 2005 and revised every year. ・2018 GADSL issued Feb. 1st 2018 ・The official GADSL will be the current English version as posted on the GADSL website: http://www.gadsl.org.
TOYOTA
BSEF Aiea Forum 2018
GADSL pre-view
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Classification P: Prohibited D: Declarable
Reason code LR: Legally Regulated FA: For Assessment FI: For Information
Source EU: REACH, Member states law etc. USA: TSCA, State law CANADA: CPCYS, CANADA Challenge Japan: Chemical Substance Control Law UN: POPs, Monitorial treaty
229: Substance Group 3284: Substances
TOYOTA
BSEF Aiea Forum 2018
GASG collaborations
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Global Automotive Stakeholder Group GASG Steering Committee
Members of automotive, supplier, chemical industries
Coordination Team
Auto OEM Suppliers
ACC (American Chemistry Council)
Auto OEM
JAPIA JCIA
(Japan Chemical Industry Association)
Auto OEM
CLEPA (European Association of
Automotive Suppliers) Cefic
(European Chemical Industry Council)
GADSL is managed by the Global Automotive Stakeholder Group. GASG is a voluntary organization of the Automotive Supply Chain.
TOYOTA
BSEF Aiea Forum 2018
1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals
34 TOYOTA
BSEF Aiea Forum 2018
Expectations to the Chemical Industry
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- Collaborate with supply chain for the information exchange + Detail substance information + Detail mixture information + Equivalent criteria for “Classification”
- Close communication for the chemical regulation + Regulatory trend + Handling of regulated substances & alternatives ( Auto industry needs to allow a significant lead-time for the evaluation & to commit to supply legacy spare parts)
- Maintain the “ hot line” among Chemical & Auto industry
TOYOTA
BSEF Aiea Forum 2018
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Thank you for your attention