Suppliers Partnership

for the Environment

Innovative Technologies for manufacturing – How collaboration leads to Environmental success for all. Presented By: Russell Brynolf

Technology & Networking Work Group

Example: Flame Treatment of TPO IP’s

• Lower Costs: - Lower Energy Usage Over Traditional

Processes - Lower Emissions - Carbon Footprint

- Significant Reduction in CO2 Emissions

- No VOC’s or HAP’s produced - Environmental Credits

• Zero Production of Solid Waste

- No Clean Up Costs - No Disposal Costs

• Reduced Cost Of Compliance • Reduced Risk Of Cost Of Non-

Compliance

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Case History – General Motors

Objectives

- To remove adhesion promoter on soft touch painted IP’s

- Remove VOC’s and HAP’s from paint process

- To improve environmental footprint

Flame Treatment implementation on IP’s and other interior injection

Molded parts in 2009 onwards

Implemented on Chevy Volt – Sonic, - Cruze, programs

Results –

• Dramatic improvement to waste stream

• Energy savings

• Increase in Operator Health and safety

• Improvement in product quality

• Significantly Reduced manufacturing cost

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Waste Stream Assessment

• Liquid paint filters

• Process air filters

• HVAC filters

• Cleaning materials

• Solvents - line flushing

• Water - flood sheets

• Water treatment chemicals

• Booth coatings

• Grate cleaning

• VOC’s

• HAP’s

• CO2

• Painted scrap material

• Paint sludge

Hazardous: Solid & Liquid waste

48 tons / yr (adpro)

< 1 ton / yr (flame treatment)

Air pollutants

810 tons / yr (adpro)

80 tons / yr (flame treatment)

Solid Waste: Landfill

25 tons / yr (adpro)

O tons / yr (flame treatment)

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Automated Flame De-flashing

Flame De-flashing Is The Process Of Removing Hair Flash & Smoothing Parting Lines Along The Edges Of Molded

Products.

The Goal Of Flame De-flashing Is To Produce A Consistent Part Of Even Quality.

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- Features: ‘Mushroom’ Flame Shape - Three Inch Flame that Spreads to Eight Inches - Wraps Around Edges and Parting Lines - Nominal Process Window Of One-Five Inches No Wasted Energy - Highly Focused Onto Desired Area Modular Construction For Easy Maintenance

Benefits: Fast Processing Speeds Reliable and Repeatable Processing Uses Significantly Less Energy Than Conventional Linear Burners

Cirqual®’ Burner Technology

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Features

High Flame Velocity

Large Process Window Ability To Reach Deep Recesses

Less Reliance On Accurate Robot Programs

Focused Flame Energy Can successfully de-flash hot, fresh parts Can successfully de-flash cold, aged parts.

Capable Of Full Integration Flame Ignition Controlled By

Robot

Benefits

Fast Cycle Times

More Consistent Part

Elimination Of Variability From Manual Operations

Higher Quality

Lower Scrap

Significant Cost Savings

Reduced Labor

Reduced Scrap

Improved Molding & Painting Quality

Features & Benefits

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Case History – GM Spring Hill

Automated Flame De-Flashing introduced

Into plant molding operations 2011

Inputs –

Energy

labor

Virgin Resin

Paint

Original process -

- Injection Mold

- Remove from mold

with 3 axis robot

- Manual Trim

- Manual flame de-flashing

- Manually place on rack

Outputs –

- High labor hours

- High Scrap rate (21%)

- Painted scrap to landfill

- High energy use

- High manufacturing cost

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Case History – GM Spring Hill

Automated Flame De-Flashing introduced

Into plant molding operations 2011

Inputs –

Energy

labor

Virgin Resin

“New” process -

- Injection Mold

- Remove from mold

with 6 axis robot

- Robotic de-gating and flame de-flashing

- Robotically place on rack

Outputs –

- labor hours reduced by79%

- Scrap rate reduced to <2%

- Painted scrap to landfill reduced by 92%

- Significant energy savings throughout plant

- Virgin resin usage reduced by 1200 Lbs./day

- Cost savings of estimated $900K / Yr.

Conclusion / Results

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The SP “Value” Connection

• GM stakeholder (JB) introduces FTS to the “right” person within GM

• Over Time:

- Testing, Development, Process Evaluation, Cost Appraisal etc.

• Discussions with Tier 1’s, Other Suppliers, & Paint Companies

• Implementation and Production Ready

• Production

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Acknowledgements

• Suppliers Partnership

• General Motors: John Bradburn, Wayne Reeder, JR Leonardi. Patrick

Vanryckeghem. Kyle Sinko

• Tier 1’s

- Inteva Products

- International Automotive Components

- Sherwin Williams & United Paint

- Calsonic Kansei

• FTS Technologies Team

• Eyses Corporation