new paint process in valladolid plant 3 wet process & 2
TRANSCRIPT
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT
New Paint Process In Valladolid Plant
3 wet process & 2 Colors Car
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 2
The Industrial Scheme
Valladolid (Spain): A western Europe plant to be converted from 60 to 45 JPH and to be modernized to produce efficiently a new car
For paint process, some opportunities:
Produce 2 tones car by using free existing capacity
Validate with few investment a 3wet process in industrial facilities
Carry over of existing sealing robots from 2 lines to 1 line to solve obsolescence
The Main Scope:
A new 2 colors Car
A new 3 wet process
A new durability performance with High Scratch resistance Clear Coat
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 3
The New 2 Tones Car
Captur:
B Segment Cross Over
5 doors
SOS: March 2013
Production Location: Valladolid
Plant Capacity: 45 JPH
21 outside colors combinations
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 4
The 3 wet Process
What’s exactly a short process?
2010: ~10 000 black vehicles produced in Valladolid with 2 wet process,
the best economical short process solution
Decision to give up this solution due to limited color range possibilities
=> Decision for 3wet / 1 FO technology
Flash Off
warm air Gun Bell Bell Bell Interior
BCi BC1 / BC 2 CCi CC
Bell
B0
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 5
The 3 wet Process: a short schedule for a short process
2011 2012 2013
T4 2010: Project Kick off
Decision
Go / noGo
June 2011 Déc. 2011 Aug. 2012
Facilities
modification
Captur SOP
Jan. 2013 MA
Product
Validation
May 2012
Captur Trials
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 6
The 3 Wet Process
Material validation with 3 suppliers involved: PPG - BASF – B&K
Homologation and lab tests on 4 critical colors
Trials in Valladolid plant without investment
Color and appearance validation on Modus painted in Valladolid Plant
30 cars manufactured with each supplier
Process Modification during 2 Shutdowns by Durr & Finitech
Process and Product optimisation on Modus Serial life to ensure
robustness before Captur SOP
Next step running: only 1 bake for sealing
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 7
The 2 Tones Process
Request for extra capacity to produce 2 tones car
=> Opportunity of free capacity in paintshop vs T&C at 45 JPH
Process Adaptation for masking and unmasking
Total Delivery Cost optimization by 2 tones limit definition
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 8
Valladolid & Captur: A success story
Successful modernization of a Western Europe Plant to make it
profitable and allow to receive a new vehicle
First successful short process implementation for Renault =>
Process decided for all Greenfield and firstly for China project
First 2-colors car with high production capacity
Commercial success confirmed for Captur !
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 9
Thank you
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 10
Annexes
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 11
Short Process or Short Processes
Sealing: 1
Or
2 baking
Waterborne
or
solventborne
Inside App. First
or Between
BC0 – BC1
Warm FO
Or
Ambiant FO
BC2 in 1
Or
2 steps
1K
Or
2K Clear Coat
2 2 x
2 x 2 x
1,5 x
2
=
2wet
Or
3 wet
2 x
96 Product & Process
solutions for A short
process
x
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 12
Valladolid Topcoat Lay out
Line A
Line B
EMU BCint BC1/2 FO CCint CC
EMU BCint BC1/2 FO CCint CC
Use Bcint for B0 application
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 13
EMU and BC Pipes moved from 10 m – new 2K PCS
2x10 m booth with Stop&Go conveyor system
B0 Station
Robot : PE133
Bell: Ecobell 2 External Charge
B0
BCi
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 14
1st color
BC+ CC Oven
Masking 2nd color
BC+ CC Oven
Inspection
Inspection Unmasking
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 15
Line A: 30 JPH
Line B: 30 JPH
EMU BCint BC1/2 FO CCint CC
EMU BCint BC1/2 FO CCint CC
Opportunity of free capacity in paintshop vs T&C at 45 JPH
Line B: 15 JPH 1st color + 15 JPH 2nd Color
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 16
2 tones Process
1st Color
Masking
Unmasking Touch up
2nd Color
Quality Check
10 Juin 2013
CONFIDENTIEL
PROPRIÉTÉ RENAULT 17
0
20
40
60
80
Sol 1 Sol 2
75 45
Op Time(min)