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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
2
Heritage
1999Feb. 2011
2005
Opel Zafira B
Opel Zafira A
Opel ZafiraTourerConcept
Sept. 2011
Opel ZafiraTourer
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
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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
AGR – Aktion Gesunder Rücken
5
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
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
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
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
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
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
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
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)
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)
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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
Mild SteelsBH & HSSDPPHSAL
3,6 % 2,6 %
27,2 % 18,7 %47,8 %
16
Material - Overview
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
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
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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
Concept/Bill of Material (BOM)
20
Carry over
Modified
New
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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
Flexibility of Underbody Rear
22
Basis top view
CNG
Rear End Carrier
Bottom view
Basis
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
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
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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
26
Body in WhiteFraming 1Motor Compartment Framing 2Inner
Framing 2 Outer
Body Shop Build Sequence
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
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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
29
Destructive Inspection
Joining Concept Overview
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
Manfred ClemenzAdam Opel AGGME Engineering19.04.2012
The new Opel Zafira Tourer