Automotive Manufacturing
July 31, 2017
Highly Crafted Interiors
Rose A. Ryntz, Ph.D.
VP Advanced Development and Material Engineering
IAC Group – Proprietary and Confidential 2
Agenda
Growth of Crafted Interiors
Feature Trends
Global Development Centers
Required Core Competencies
Global Manufacturing Capability
Innovative Advanced Projects
Global Know-How and Technology
IAC Group – Proprietary and Confidential 3
Advanced Technology
Interior Market - Feature Trends 1997
Woodgrain
Cell Phone Holder
Storage
Radio with
Casette Player
Soft Arm Rests
IAC Group – Proprietary and Confidential 5
Industry Update 2017
JD Power Consumer Quality Survey
1) Reliability/Durability
2) Interior
Finding a vehicle interior to be
comfortable and of high quality is the
second most frequently cited reason for
buying a new vehicle.
3) Exterior Styling
4) Gas Mileage
5) Quality of Workmanship
6) Dealer was Convenient/Liked Dealer in Area
7) Performance
8) Advanced Technology
9) Like the Image Vehicle Portrays
10) Safety
16% of poor quality issues cited by
consumers were related to interior:
Materials scratch/scuff easily
Excessive wind noise
Odor/VOC (China)
IAC Group – Proprietary and Confidential 6
Advanced Technology
Interior Market – Feature Trends 2017
Leather Cut &
Sew
Components Multi-color
Multi-texture
Mass Reduction
Patterned Metallic
Decorative
Accent Stitching
Multiple
Information
Displays
Doubled Up Stitch Patterns
Exterior to Interior Cues
Surface Decorations
Connectivity
Storage
Safety
Environmental
Decorative Lighting
Durable Materials
IAC Group – Proprietary and Confidential 7
Craftsmanship
Glass – 2017 Lexus LS 500
Use of Exotic Materials, Sewn Components, and Integrated Electronics
IAC Group – Proprietary and Confidential 8
IAC Global Cut & Sew CapabilityTo
da
y2007
Pattern Development Part Production Product Lines Manufacturing
Locations
INDUSTRY SHIFT• OEM’s desire for brand differentiation
• Consumer demand, luxurious appearance
• Consumer demand, soft touch interior
2
Vehicle
Platforms
3
Parts
33 100+
DOOR
Armrest, Upper, Bolster
CENTER CONSOLES
Armrests, Side Panels
INSTRUMENT PANELS
Seamless Uppers, Binnacles,
Lowers, Glove-box Outers,
Seatbacks, Headliners, Visors
Armrests , Bolsters
Toluca, MX
Saltillo, MX
Arteaga, MX
Ramos, MX
Hermosillo, MX
Iowa City, US
Warren, US
Coleshill, UK
Plattling, Germany
Hodonin, Czech
Lozorno, Slovakia
Hangzhou, China
Opoloe, Poland
Saltillo, MX100% Outsourced
100% Vertical Integration
Troy Trim Lab
Hangzhou Trim Lab
Coleshill Trim Lab
Ebersberg Trim Lab
CAPABILITY
IAC Group – Proprietary and Confidential 9
Concept to Production
Concept Design & Validation Production
IAC Group – Proprietary and Confidential 10
Prototype Development
Build Support
Rapid prototype capabilities:
FDM (fuse deposition modeling) – extrudes layers of ABS
SLA (stereo lithography) – laser beam cures photochemically
reactive resin; mimics nylon
SLS (selective laser sintering) – uses laser beam to build a part;
mimics PP
Part fabrication & mock ups
Process development/optimization
IAC Group – Proprietary and Confidential 11
Craftsmanship
Effect of Stitch Type on Application
Stitch and material join can affect how part surface appears after decoration
Join sew “selvage” can change design of part
Foam in Place (FIP) Sealing ProcessSlush Skin Sewing Sealing Tape Foam in Place
IAC Group – Proprietary and Confidential 14
NC Cut File
RH Topper + 3 Inner Binnacles + 2
Outer Binnacle Facings 1 Yd 0.2”
Steel Rule Die
RH Topper + 1 Inner Binnacle + 2
Outer Binnacle Facings 1 Yd 3.0”
Coverstock Pattern Nesting
Optimizing Material Usage
IAC Group – Proprietary and Confidential 15
Craftsmanship
Laminating and Edge Wrapping
Very manual process, seam alignment very labor intensive and dependent upon
adhesive selection
IAC Group – Proprietary and Confidential 16
Auto Edge Wrap- Servo
driven (x4)
Shuttle Heater-
interchangeable heater pack
Edge wrap heaters- IR (x2)
and hot air (x2)
Lamination/Edge Fold
Manufacturing Tools
Vision system for
alignment check of seam
IAC Group – Proprietary and Confidential 18
Cut & Sew Global Production
IAC Regional Support
Manufacturing Facility
Design, Technical, Commercial Center
IAC Group JV
IAC Group – Proprietary and Confidential 19
Central European Cut & Sew Lab
Ebersberg, Germany
Leather
Splitter
Edge Skive
Salvage Trim
Join
French Seam
8mm
French Seam
6mm
French Seam
8mm
French Seam
8mm
Oven
Adhesive
Spray Booth
Heat Seal
Seam Tape
Punch
Machine
IAC Group – Proprietary and Confidential 20
Northern European Cut & Sew Lab
Coleshill, United Kingdom
Small Press
Lamination
Seam alignment
Fixture
Twin needle machine Single needle Machine
Pattern development
and digitising
CNC leather hide cutting
IAC Group – Proprietary and Confidential 21
North America Cut & Sew Lab
Troy, MI, USA
Digitizing
Station
Leather
Splitter
Gerber
CutterSalvage Trim
JoinFrench Seam
6mm, 8mm, 10mmDeck Seam
2D Automatic
Edge SkiveHeat Seal
Seam Tape
Adhesive Roll
Coat
Press
Lamination
IAC Group – Proprietary and Confidential 22
China Cut & Sew Lab
Hangzhou, China
French Seam
6mm, 8mm, 10mm
2D Automatic Deck SeamAirbag sewing
machineFunction Seam CNC leather hide cutting
IAC Group – Proprietary and Confidential 24
IAC Group Asia
Highlighting Cut & Sew Facilities
Beijing (Songjiang-JV)
Beijing
Changshu
Changshu (Songjiang-JV)
Chongqing
Hangzhou
Shanghai Engineering Center
Shanghai (Songjiang-JV)
Shanghai
Shenyang (Songjiang-JV)
Tianjin (Songjiang-JV)
Wuhan (Xiang Xing-JV)
Wuhan (Songjiang-JV)
Yantai
China
Chakan I, Pune
Chakan II, Pune
Manesar I, Haryana
Manesar II, Haryana
Pune
Thane
India
Yokohama
Japan
Seoul
Rayong
Thailand
Korea
Manufacturing Facility
Design, Technical, Commercial Center
IAC Group JV
IAC Group – Proprietary and Confidential 25
IAC Group North America
Highlighting Cut & Sew Facilities
Albemarle, NC
Alma, MI
Anniston, AL
Dayton, TN
Fremont, OH
Greencastle, IN
Holmesville, OH
Huron, OH
United States
Maple
CanadaArteaga
Hermosillo
Monterrey
Puebla
Mexico
Manufacturing Facility
Iowa City, IA
Madisonville, KY
Mendon, MI
Montgomery, NC
Old Fort, NC
Port Huron, MI
San Antonio, TX
Sidney, OH
Spartanburg, SC
Springfield, TN
St. Clair, MI
Strasburg, VA
Warren, MI
Wauseon, OH
Queretaro
Ramos
Saltillo
Toluca
IAC Group – Proprietary and Confidential 26
IAC Group Europe
Highlighting Cut & Sew Facilities
United Kingdom
Coleshill
Elmdon
Halewood
Scunthorpe
Sunderland
Germany
Bad Friedrichshall
Celle
Hamburg
Lambrecht
Plattling
Straubing
Zwiesel
Romania
Bals
Spain
Logroño
Vitoria
Poland PoznanOpole
Netherlands
Born
Belgium
Grobbendonk
Sweden
Färgelanda
Låssby
Skara
Carpets & Acoustics
Plastics
Czech Republic
Hodonín
Přeštice
Zákupy
Slovakia
Lozorno
IAC Group – Proprietary and Confidential 27
Mexico Cut & Sew Manufacturing
Gerber Cutter
Salvage Trim
JoinFrench Seam
6mm, 8mm, 10mmDeck Seam2D Automatic
SewingEdge Skive
Heat Seal
Seam Tape
Press
Lamination
Bladder
Lamination
Manufacturing locations utilize same equipment as utilized in development
IAC Group – Proprietary and Confidential 28
Flaming line Wrapping and Press Lamination
Spray Line Wrapping Part Storage
IAC China Hangzhou Plant
IAC Group – Proprietary and Confidential 30
Cut & Sew Development
Global Advanced Projects
New Cut & Sew materials
e.g. wood veener with fleece backing and laser perforation
2 D sewing pattern / 3D Robot sewing active
surface materials
e.g. laser perforation decor with backlit
heated surfaces
High crafted combination of materials
e.g. use of fabrics/mesh/foam
e.g. Stitching of Skins
Seamless airbag opening on Cut & Sew
materials
e.g. PU Foil, Alcantara, Leather by weakening with ultra
short pulse laser (Femto)
IAC Group – Proprietary and Confidential 31
5 Global Cut & Sew Tech Centers
IAC Troy NA
IAC Ebersberg EUPremium Products
Volvo V/S 90 EUNissan Maxima NAAudi Q7 EU
Expertise in all types of sewing styles inc. stitching &
design support
Global pattern development (cut, scan, documentation)
Global cut & sew decor material know-how
(leather, PVC, PU foil, fabric, Alcantara)
Expertise with all types of constructions
(foam, spacer textile, rolled foam)
Global laminating know-how (process, glue)
IAC Core Technologies Summary
Cut & Sew Crafted Surfaces
What is Required?
IAC Group – Proprietary and Confidential 32
Cut and Sew Development Core Competencies
Vertically Integrated Process
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