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WINNER |
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(click on the picture to see a larger illustration - it opens in a new window, close that window to return here) |
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| Description: | Door Trim & Hardware Module | Model: | Caliber, Compass and Patriot |
| OEM: | Chrysler LLC | Model Year: | 2006 |
| System Supplier: | Grupo Antolin | Generic Resin Type: | PP |
| Molder/Processor: | International Automotive Components | Resin Trade Name: | N/A |
| Toolmaker: | HiTech | Grade: | 702-20 |
| Material Supplier: | Dow Automotive | Other Innovative Features: | Includes two shot bolster winner from last year |
| Most Innovative Feature: | Integration of components, this unique module concept combines all door hardware components and the trim panel into one module, directly sequenced into the plant fully tested vastly reducing amount of online stations at vehicle assembly plant | Forming Process: |
Injection molding and two shot for the bolster |
| Weight Savings: | conventional build are mainly around 10% saving of total system weight. In carrier modules ranges from around 600g for a small module like Wrangler up to 2500g for a module like Dodge Ram | First Time Process Used? | This is the first of its kind in the US market place. Grupo Antolin introduced the concept first in Europe on vehicles like the Renault Megane, Seat Leon, Seat Altea and more |
| Cost Savings: | Estimates range from $10 to $17 per vehicle total savings to OEM. Majority comes through assembly operation reductions and parts being directly sequenced to line | Previous Process: | The current market options are 1. Conventional build: all hardware is assembled separately into door at vehicle assembler. 2. A hardware module is assembled to the vehicle with all hardware but still requires a finished trim to be assembled on top |
| Cost Avoidance: | Sequencing costs are vastly reduced, OEM storage space reduced. If new plant then major reduction in line and operators required (dependant on union agreement with OEM) | Transferable to Other Vehicles: | Yes, application already in place with other OEMs in Europe. Discussions in place for further applications of this concept continue |
| Benefits to Consumer: | |||
| No Glass fiber reinforced plastic carrier required | |||
| Method Comments: | |||
| None other than impact properties which any trim requires for side impact | |||
| Innovations/Improvements: | |||
| Deep draw towers for regulator mounting, very careful design in lifters for tool. Control of edge condition important to maintain seal and fit condition of door | |||
| Safety Improvements: | |||
| Part met all requirements for Chrysler to gain 5 star side impact rating | |||
| Environmental Comments: | |||
| Less fasteners as trim integrates many of the attachment features | |||
| Additional Comments: | |||
| This has been a very successful module launch for Chrysler | |||
| Summary: | |||
This unique assembly combines all door hardware components plus trim panel in a single module produced via injection molding and the 2-shot bolster process. It is directly sequenced into the plant, arriving fully tested to reduce door dress-up at the vehicle assembly plant, and offers 10% weight and $10-$17 USD OEM cost savings per vehicle. |
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