Actros Innovative Modular Door Systems Feature Integrated Subsystems
2003 DaimlerChrysler Actros MP2

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Nominee Number: 27 Result: Finalist
Category: Body Interior Description: Actros Innovative Modular Door System
OEM: DaimlerChrysler Model: Actros MP2
Model Year: 2003 System Supplier: Delphi
System Contact: Klaus Caspers System Phone: 49 202 291 3441
Model/Processor: Seeber Molder Contact: Herr Heckmueller
Molder Phone: 49 6142 844 607 Toolmaker: Deuschle
Tool Contact: Herr Kreitmeier Tool Phone: 49 7153 3000 31
Material Supplier: Sabic Material Contact: Herr Rob Donners
Material Phone: 31 464767899 1155 Generic Resin Type: HCPP
Resin Trade Name: Stamytec CX02 Grade: -
OEM Engineer: Uwe Voss OEM Title: Project Manager
OEM Phone: 49 7031 9082041 Name of Nominee: Suresh Shah
Nominee's Company: Delphi Corporation Nominee's Address: 1401 Crooks Road
Troy, MI 48098
Nominee's Phone: 248-655-8695 Nominee's Fax: 248-655-8255
Nominee's Email: suresh.d.shah@delphi.com    
Summary: An innovative modular door system featuring integrated subsystems which make up the entire door system.  Cost savings: 70% due to labor reduction during assembly.
Most Innovative Feature: An innovative modular door systems feature integrated subsystems, which make up the entire door system, providing the most cost-effective approach.
Other Innovative Features: Total door system assembly include the door trim integrates the inside door handle, the pull grip, speaker grill and speaker, air flow channel with air vent, map pocket, the electronic control module and the switches etc.
What Forming Process? Injection Molding with hot manifold system and injection speed profile .
First Time Process Used: Yes, integrating up to 85 percent of the door's content in the modular door.
Previous Process: Separate pieces injection molded. 
Tooling Innovations: Special hot manifold system to avoid angel hair problems associated with high flow PP.
New Material Developments: Commercial PP but specific color concentrate for MOLDED-IN-COLOR.
Weight Savings: N/A because of higher content.
Cost Savings: 70 % labor reduction in customers facility.
Cost Avoidance: 90 % logistics reduction and 90 % first time quality improvement in customers value stream.
Direct Consumer Benefit: Part integration  and integrated subsystems reducing significant cost saving for entire door system, quality improvement esp. FTQ in assembly of OEM.
Translates to Other Vehicles?: Yes, OEMs are accepting this concept for future vehicles.
Safety Benefits: N/A.
Environmental Benefits: 1. Molded-in-color, elimination of paint. 2. All PP  for door trim module, easy to recycle.
Additional Comments: By designing and manufacturing these components integrated in the modular door, Delphi has the capability to simplify the installation process by integrating up to 85 percent of the door's content in the modular door.The modular door system design makes the door more reliable and more economical by providing a majority of the door components in one integrated system that is pre-tested and easily installed, avoiding many of the ergonomic issues found in the assembly of a conventional door.