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Removable Hard Top with "Freedom Panels" |
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| OEM: | DaimlerChrysler | Model: | Jeep Wrangler |
| Model Year: | 2007 | Molder/Processor: | ABC Group Inc. |
| System Supplier: | Meridian Automotive Systems | Molder Contact: | Robert Drascic |
| System Contact: | Matt Vagi | Molder Phone: | 905-454-4465 x 236 |
| System Phone: | 313-253-3555 | Material Supplier: | Salflex Polymers (ABC Group) |
| Toolmaker: | Century Tool | Material Contact: | Brian Yawney |
| Toolmaker Contact: | Mike Cummings | Material Phone: | 416-741-0273 |
| Toolmaker Phone: | 810-629-0784 | Generic Resin Type: | GFPP |
| OEM Permission: | Yes | Grade: | 815 |
| OEM Engineer: | Michael Uhlmeyer | Nominator: | Robert Drascic |
| OEM Title: | Manager TK / JK BIW | Nominator's Company: | ABC Group Product Development |
| OEM Phone: | 313-653-5185 | Nominator's Address: | 303 Orenda Drive Brampton, ON, L6T 5C3 |
| Forming Process: | Compression molded SMC, automated drilling, assembly, bonding, and spatter-coat painting." No "Functional weight savings realized by splitting the current one-piece top assembly into three separate assemblies. | Nominator's Phone: | (905) 454 4465 x 236 |
| First Time Process Used? | No | Nominator's Email: | robertd@abcgrp.com |
| Weight Savings: | Panels weigh less than 15 pounds | Cost Savings: | Over $5,000,000 in annual piece price reduction |
| Cost Avoidance: | 40% reduction in initial tooling investment and lighter components in assembly plants reduce strain on operators during installation process which will result in fewer chronic injuries. | ||
| Summary: This single piece, blow-molded step assist replaced a 31-piece plank assembly, while maintaining metallic color, Class-A surface-finish requirements. Multiple savings in tooling investment, piece, and assembly costs were achieved. ABC utilized in-house suppliers to develop materials and tools, which allowed for the replacement of a painted TPO cover. Use of plastic for the step assist greatly reduced overall system corrosion potential, improved assembly NVH performance, and reduced system weight. | |||
| Most Innovative Feature: Single Piece Blow Moulded in Metallic Colour Assist Step utilized to replace a 31 piece plank assembly while maintaining Class A surface finish requirements. | |||
| Other Innovative Features: ABC utilized in house suppliers to develop materials and tools which allowed for the replacement of a a painted TPO cover with a blow moulded product. Use of Plastic for assist step greatly reduced overall system corrosion potential. | |||
| Previous Process: 1 Painted cover, 1 roll form support structure, 2 stamped extension brackets, 2 injection moulded end cap supports, 24 fasteners, 1 locator | |||
| Additional Details: This is the first time that a blow moulded part straight out of the mould (without further processing) is being used to replace a painted component. | |||
| Further Comments: | |||
