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The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering...

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1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer Manfred Clemenz Group Leader Body in White Manufacturing Engineering Body
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Page 1: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

1

Fügen 2012Bad Nauheim April 19, 2012

The new Opel Zafira Tourer

Manfred ClemenzGroup Leader Body in White

Manufacturing Engineering Body

Page 2: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

2

Heritage

1999Feb. 2011

2005

Opel Zafira B

Opel Zafira A

Opel ZafiraTourerConcept

Sept. 2011

Opel ZafiraTourer

Page 3: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Range of Products

3

Agila

• Length: 3740 mm

• Height: 1590 mm

• Width: 1680 mm

Meriva

• Length: 4288 mm

• Height: 1615 mm

• Width: 1812 mm

Zafira B

• Length: 4467 mm

• Height: 1635 mm

• Width: 1801 mm

Zafira Tourer• Length: 4658 mm• Height: 1685 mm• Width: 1884 mm

Page 4: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Flex7 Seating System

4

• New standard in cabin flexibility and quality

• Unique Lounge Seating System

• Second row consists of three separate, individual seats

• Combination of longitudinal and lateralmovements possible

Page 5: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

AGR – Aktion Gesunder Rücken

5

Page 6: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Shared Development Timing/Situation

6

Productdevelop-ment

Design

ProjectManage-ment

Homeroom

Warren, Michigan

Ruesselsheim

Program Initiation / Package Freeze Production Release Start of Production

Page 7: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

7

Bochum: 3219 employees

Models: Astra Classic HB5Astra Classic CaravanZafira BZafira Tourer

Capacitiy: 174.567 cars/year

Plant Bochum, Germany

Page 8: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

8

Astra Classic HB5

Astra ClassicCaravan

Zafira B

2009 2010 2011 20132012

ZafiraTourer

EOP 12/2014

EOP 12/2014

SORP

26.09.2011

Zafira Tourer Bodyshop Integration

EOP 12/2015

Page 9: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

9

Panoramic windscreen: Bright and airy atmospherePanoramic windscreen: Bright and airy atmosphere

Improved forward visibility:

• Slim A-pillars

• Large side windows

• Rear view mirror on door shoulder (pedestal mounted)

Improved forward visibility:

• Slim A-pillars

• Large side windows

• Rear view mirror on door shoulder (pedestal mounted)

Highlights

Page 10: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Slim split A-Pillar - Cab forward design

1010

windshield positionZafira B

windshield positionZafira Tourer

Windshield position comparisonZafira Tourer / Zafira B

Page 11: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Panoramic Windscreen & Large Sunroof

11

• Broad use of the innovative windscreen within the Opel model range

• Unique feeling of spaciousness

• Light-flooded interior space

• Broad use of the innovative windscreen within the Opel model range

• Unique feeling of spaciousness

• Light-flooded interior space

Page 12: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

12

FlexFix® 2+2 rear carrier system• 4-Bike Carrier “2+2”

unique to Opel Zafira Tourer

• 2-Bike Carrier always usable on customers demand (optional accessory)

• Excellent ergonomicsfor bike loading

Page 13: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Innovative Assistance Systems

13

• Adaptive Cruise Control (ACC)• Collision Mitigating Braking (CMB)• Following Distance Indication (FDI)• Forward Collision Alert (FCA)• Side Blind Spot Alert (SBSA)• Rear View Camera• Lane Departure Warning (LDW)

• Advanced Park Assist (APA)

• Traffic Sign Recognition Plus

• Advanced Forward Lighting (AFL+)

with Intelligent Light Ranging (ILR)

Page 14: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Dimensions

14

+57+191

+50

+96+83

+83+74

Frontal area (A)2,64 m² (+0,19 m²)

Coefficient of drag (cD)0,304 (-0,01)

Drag area (cD x A)0,80 m² (+0,04 m²)

Luggage volume 710 l – 1860 l (+65 l / +40 l)

Tank capacity60 l (+2 l)

Page 15: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Zafira B

Zafira Tourer

15

Material - Overview

BH & HSS47,8 %

Mild Steel27,2 %

DP18,7 %

AL2,6 %

PHS3,6 %

Mild Steel49%HSS

42%

DP 4%

TRIP4%

AL1%

Mild SteelsBH & High Strength SteelDPPress Hardened SteelAluminum

Page 16: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Mild SteelsBH & HSSDPPHSAL

3,6 % 2,6 %

27,2 % 18,7 %47,8 %

16

Material - Overview

Page 17: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

• PHS

• B-pillar reinforcement

• door beams

• DP

• seat cross member

• roof frame middle

• rocker

PHS B-Pillar designed for robust impact behavior and trigger to avoid cracks

17

Material - Overview

Page 18: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Hang-On Parts - Hood concept

18

Zafira B Zafira Tourer

Area: 0,95 m²Mass: 10,7 kg

Area: 0,99 m²Mass: 5,7 kg

Mass -5 kg

Steel Innovation Price 2006Benchmark for sheet metal hoods since 2005

Page 19: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

19

Hood- 5,0 kg

Front Doors- 1,0 kg

Rear Doors- 1,9 kg Tailgate

-0,1 kg

Compared to Zafira B

Hang-On Parts - Weight Savings

Page 20: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Concept/Bill of Material (BOM)

20

Carry over

Modified

New

Page 21: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Normal Roof

Panoramic Glass Roof

FlexFix®

Rear Carrier

Normal Roof

Panoramic Glass Roof

FlexFix®

Rear Carrier

21

GASpowered

GASpowered

RHD

Only 8 Variants

LHD

Body Shop Integration

Page 22: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

Flexibility of Underbody Rear

22

Basis top view

CNG

Rear End Carrier

Bottom view

Basis

Page 23: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

23

Storage

MaterialInput

General Assembly

TrailerUnloading

Point

M

Q

N

P

R

S

T

O

F

H

J

A

B

C

D

E

G

Building D-3

2 5 93 4 6 7 8 10 11 12 13 14 15 16 17 18 232119 20 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Building D-4

0

2 5 91 3 6 7 8 10 11 12 13 14 15 16 17 18 232119 20 224

M

Q

N

P

R

S

T

O

F

H

J

A

B

C

D

E

G

UnderbodyMarriage

Repair

SpecialVehicle

Body Framing Respot

Buffer

MotorCompartment

A-33xx

Body In White (Line 209)

Dash Panel A-33xx

TailgateA-3370

Rear DoorRH A-3370

Front DoorLH A-3370

Underbody MarriageLine 2

Framing Inner

Underbody MarriageLine 1

Underbody RearA-3370

Side PanelA-3370

Side PanelA-3370

Storage

LongitudinalFront LHA-33xx

Storage Area

Body In White (Line 204)

Rear DoorLH A-3370

Body In White (Line 210)

Storage Area

Stor

age

Sid

e Pa

nel

A-3

300/

3301

Batt

ery

Cha

rgin

g

Storage

TrailerUnloading

Point

Storage Area

Sto

rage

Are

a

Sid

e Pa

nel

A-3

300/

3301

Indirect Area

LongitudinalFront RHA-33xx

Indirect Area

Dash PanelA-33xx

Storage Area

Das

h Pa

nel A

-33x

x

RearDoorRH

RearDoorLH

FrontDoor

RH

Floor PanelFrontA-33xx

-O--K- -L- -M- -Q--N- -P-

A HGDCB

Indirect Area

StorageArea

Subs

Doo

rsA

-337

0 Storage Area Storage Area

LongitudinalFront LH/RH

FrontDoor

RearDoor

FloorPanelFront

Extension

Retooling Rearrange

Shop FloorTransportation

Equipment

SP-R

epai

r

WheelhouseRear A-3310/3370

Astra Classic+

Zafira B

SidePanelInner

Motor-compart-

mentUnderbody Rear

UBRA-3300

Side Panel

F

RoofA3370

E

Rear DoorA-3310

LH

Rear DoorA-3310RH

TailgateA-3310

Rear Rails

UBR

A-3

310

Stor

ag

e A

rea

Storage

Dash-panel

Tailgate

Storage Area

Storage Area

Stor

ag

e A

rea

RoofA-3310

Storage Area

StorageArea

RoofA-3300

TailgateA-3300

HoodA-3370

MPC-Area

Framing Outer

New

Sto

rage

Are

aStorageArea

FrontDoor

LH

Flexibility of the Body Shop

Page 24: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

24

Area Strategy

Lowers

Front Rails Rearrange

Dash Panel Rearrange

Motor Compartment Rearrange

Floor Panel Front Rearrange

Rear Compartment Rearrange

Underbody Complete Reuse

Uppers

Bodyside Inner Rearrange

Bodyside Outer Rearrange

Framing Inner Reuse

Framing Outer Rearrange

Framing Respot Reuse / NEW

BIW Reuse

Closures

Front Doors Rearrange

Rear Doors Rearrange

Tailgate Rearrange

Hood Rearrange

New Rearrange Reuse

• newly integrated system (new tooling,machinery and equipment)

• All geo tools new• Grippers/Weldguns

completely or partly new

• Rebuild cell by using existing components

• Partly or complete new equipment infrastructure

• New or modified loading areas

• All geo tools new• Grippers/Weldguns

reuse, modified or partly new

• Keep line control, loading/unloading areas and material flow

Investment:100%

Investment:45-80% of New

Investment:45-56% of New

Production Lines Reuse

Page 25: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

25

Clamping Holes 40,1 +0,1 Clamping Holes 25,1 +0,1

#1

Transport Holes

#2 #3 #4Common for all GCV Projects

all clamping also in height (Z)

bottom view

front

Clamping and Transport System

Page 26: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

26

Body in WhiteFraming 1Motor Compartment Framing 2Inner

Framing 2 Outer

Body Shop Build Sequence

Page 27: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

27

Joining Concept Overview

MIG brazing

Laser brazing

Structural bonding

Sealing

Weld spots

Weld studs/nuts

Clinch spots

Bolting

Hemming

Page 28: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

28

Length MIG seams

Laser brazing

Length structural bonding

Length sealing

No. of weld spots

No. of weld studs

No. of clinch spots

No. of bolts

WSE

Zafira B Zafira Tourer Difference

0,75 m 1,11 m + 0,36 m

0 m 1,25 m +1,25 m

8,5 m 5,8 m - 2,7 m

20,5 m 18,0 m - 2,5 m

4937 5074 + 137

77 147 + 70

10 53 + 43

82 86 + 4

5646 5786 +140

Joining Concept Overview

Page 29: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

29

Destructive Inspection

Joining Concept Overview

Page 30: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

ShreddingPre-treatment Adv. Sorting Technology

& minimum dismantling

Fe-scrap

Shredder-Fibres

Shredder-Granules

NFe-Metals Disposal

Shredder-Sand

4% (fluids/tires)

7%

5%

4%

75%(incl. metals from pre-treatment + dismantling)

1%(non-metallic re-use)

Percentage of reference weight: ~ 96 %

for thermal energy gain

Vehicle Recycling

Source: AUTOBILD

30

Page 31: The new Opel Zafira Tourer - European Coatings€¦ · Manfred Clemenz Adam Opel AG GME Engineering 19.04.2012 1 Fügen 2012 Bad Nauheim April 19, 2012 The new Opel Zafira Tourer

Manfred ClemenzAdam Opel AGGME Engineering19.04.2012

The new Opel Zafira Tourer


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