Manufacturing World Class Interiors

Raymond E. Kalisz, PE

North American Director

Technologies & Standards

Agenda

2

Weakening by Milling (WBM)1

Wood Decoration2

Smart Surfaces3

Weakening by Milling (WBM)

World Class Interior Craftsmanship requires the right materials and processes to ensure harmony

WBM – World Class Manufacturing For Seamless Passenger Airbag Systems

Oxford Dictionary_________________________________

Craftsmanship/’kraf(t)smenShip/

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noun

1. skill in a particular craft.

The quality in design and work shown in something made by hand; artistry

Weakening by Milling (WBM) provides the optimal combination for craftsmanship and manufacturing

Weakening Options For Seamless PAB Systems

Laser

Robotic Milling

CNC Milling (WBM)

Mold in Seam

Machine Capability

(30 cycles)

Targets Laser Robot WBM (CNC)

sigma n/a n/a 0,012 0,003

Cm > 1,97 4 2,694 12,707

Cmk > 1,97 2,694 9,965

According to :

FAU-S-PS3-0221

Targets Laser Robot CNC

sigma n/a n/a 0,012 0,01

Cp > 1,67 2,15 3,1

Cpk > 1,76 1,71 0,83 2,2

WBM is the most capable process

Capability Study of Weakening Options

Residual Wall Thickness

Part Thickness

HEADMOVEMENT

7

WBM is simple, robust and flexible

WBM – Provides Many Pattern Options

Pendulum test results @LT (-35ºC) opening acceleration:

WBM can match the same opening curve as Laser

Laser

WBM

WBM – Opening Forces

WBM – Video of Operations

Faurecia’s WBM process uses standard robust components with a proprietary router bit design

Wood Decoration

World Class Interior Quality in Decoration requires a focus on every step in the process

Wood Decoration – Ligneos Introduction

Oxford Dictionary_________________________________

Quality/ˈkwälədē/

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noun

1. the standard of something as measured against other things of a similar kind; the degree of excellence of something.

The Ligneos design can be adapted with many combinations of interior trim materials

Flexibility In Design Concepts With Multiple Materials

Aluminum

Synthetic

Ligneos - Wood

Carbon Fiber

Global Decoration Market

Ligneos process requires combination of high skills in Woodworking and Interiors Manufacturing

Reconstitution

(glue/slicing)

Ligneos

LaminationSanding Flexing

Laser 2D

From The Forest To Interior TrimsIndustrial processes & detail craftsmanship sequences

Pre-forming of

wood cut kitsInjection of carrier

Handcraft

StainingMilling Final top coat

Open pore &

inspection

Primer

sandingGluing carrier &

wood shell

Primer

spray

Manual

Texturing

Sustainable plantation

Membrane prefixing

covering

Photo prefixing

Veneers

jointing

Log selection Log slicingVeneer

selection

Bleaching

Dyeing

Antiox

FOCUS

Start-to-finish control is the key to excellence

From The Forest To Dash TrimsIndustrial processes & detail craftsmanship sequences

Veneer sorting &

complexing LIGNEOS in

Lombardia ITALY

Sustainable harvesting & log

sorting

TABU imports from

Cameroon

Manual wood complex

wrapping & hand finishing in

Puebla, MEXICO

FOCUS

The logistics must be managed as part of the quality process

Ligneos Upgrading

Many possibilities can be envisioned

Smart Surfaces

World Class Interior Innovation requires dedication as vision while maintaining manufacturing excellence

Smart Surfaces Introduction

Oxford Dictionary_________________________________

Innovation/ˌinəˈvāSH(ə)n/

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noun

1. a new method, idea, product, etc

Smart Surfaces Market

Flexible displays are booming on the consumer markets

The Smart Surfaces Interiors market will continue to grow rapidly

Smart Surfaces Future with Faurecia