| Summary: |
A "Tough Class 'A' (TCA)" SMC has been developed to improve
the defect resistance of closure panels. By incorporating a new polyester
base resin chemistry, it provides a superior matrix toughness over
conventional SMC. No direct cost savings but over $15M in annual cost
avoidance due to improved OEM paint shop first run capability. |
| Most Innovative Feature: |
TCA SMC incorporates a new polyester base resin chemistry
providing a superior matrix toughness over conventional SMC. This allows for
OEM paint shop capability through exceptional processing performance with a
95% elimination of SMC defect rates. |
| Other Innovative Features: |
TCA SMC exhibits improved micro-crack resistance quantified
through DOE's, new test method development and stress strain evidence. Since
launch in May of 2001, TCA has eradicated 95% of the 63,000 units repainted
annually due to SMC defects. |
| What Forming Process? |
Conventional High Pressure Compression Molding. |
| First Time Process Used: |
TCA SMC was launched on the Ford Thunderbird and Explorer
Sport Trac in May of 2001. Eight other Ford vehicle products lines
incorporate TCA SMC body closure panels. |
| Previous Process: |
Replaces current / conventional SMC without any tooling,
molding or processing modifications and has significantly reduced internal
scrap. |
| Tooling Innovations: |
Conventional tooling is utilized. |
| New Material Developments: |
TCA SMC exhibits a 70% increase in resin tensile
properties, water absorption % by wt. is reduced in half and over an 80%
reduction in pop defects as compared to conventional SMC materials. |
| Weight Savings: |
SMC provides a higher strength to weight ratio vs. steel or
aluminum. |
| Cost Savings: |
There is no direct cost saving associated with this
new/modified SMC material. |
| Cost Avoidance: |
Over $15M in annual cost avoidance is recognized due to
improved OEM paint shop first run capability with reduced SMC pop defects /
vehicle repaints. |
| Direct Consumer Benefit: |
A 2 "Things Gone Wrong" (TGW) reduction per vehicle line
has been achieved. |
| Translates to Other Vehicles?: |
Other OEM's are investigating applications for this
material. |
| Safety Benefits: |
Due to significant reductions in paint defect related
rework/repair at both the supplier and OEM facilities, fewer ergonomic
issues are evident such as carpel tunnel syndrome. |
| Environmental Benefits: |
As much as 250,000 lbs annual VOC's are avoided from the
reduction in repaints and 4.5 M lbs of SMC scrap parts are not sent to
landfills. |
| Additional Comments: |
Improved process ability and defect reduction with TCA SMC
has breathed life back into the SMC industry. SMC use on select Ford OEM
vehicles will continue to provide advantages of corrosion resistance, high
strength to weight ratio, Improved impact resistance, lower capital tooling
costs and unique design flexibility. |
