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