| Summary: |
Development of a technology for improved heat transfer
(heating/cooling) and process control for slush molding.
Cost savings: 30-40% from cycle time reduction, 50% from capital
cost reduction and 80% energy reduction. |
| Most Innovative Feature: |
A proprietary method of improved heat transfer
(heating/cooling) and process control for slush molding.
This technology is the first in the industry. |
| Other Innovative Features: |
Noise is reduced from needing hearing protection to the
level of normal conversation. The
need for expensive high bay manufacturing building is eliminated. |
| What Forming Process? |
Slush molding. |
| First Time Process Used: |
Yes. |
| Previous Process: |
Conventional hot air or hot oil slush molding that utilize
inefficient heat transfer methods and are less environmentally friendly. |
| Tooling Innovations: |
Tool metallurgy strengthening innovations and tool heat
transfer innovations were required to implement this new technology. |
| New Material Developments: |
The new technology will enable Collins & Aikman's new
and continuing material developments to achieve improved cost and improved
performance. |
| Weight Savings: |
None. |
| Cost Savings: |
30-40% cycle time reduction, 40-50% capital cost reduction,
and 70-80% energy reduction were all achieved. |
| Cost Avoidance: |
Lower cost manufacturing site/building can be used due to
not requiring high bay and special equipment foundations.
Also, the equipment can be easily relocated. |
| Direct Consumer Benefit: |
No. |
| Translates to Other Vehicles?: |
Yes. |
| Safety Benefits: |
Manufacturing noise is reduced from 88db to 77db.
NOx emissions are eliminated. |
| Environmental Benefits: |
NOx emissions are eliminated. |
| Additional Comments: |
The significant reduction in cycle time achieved by this
innovation has allowed slush molding to be used in high volume
applications that were previously considered economically unfeasible. |
