The new manufacturing facility where Lotus will build its Evija all-electric hypercar is being readied for final prototype production. Shortly after production commences in mid-2020, the first of 130 customers can expect deliveries of their cars. The first year’s production allocation is already designated to customers around the world.
The hall is situated trackside next to Lotus’ 3.5-km circuit which has hosted testing and shake-down sessions with many Formula 1 legends such as Ayrton Senna, Emerson Fittipaldi, Jim Clark and others. The result is a versatile and inspiring workspace that will see Lotus hand-build up to 130 examples of the Evija.
“This is now the newest car production facility in the world, and to witness it move from the drawing board to reality has been deeply satisfying. It’s testament to the commitment of all involved, and is the perfect sleek and high-tech production home for the Evija at our iconic Hethel headquarters,” said Phil Popham, CEO, Lotus Cars.
“With our new factory ready, we are ahead of the pack in the emerging EV hypercar segment and 100% ready for some healthy competition,” he added.
Work on the new Evija factory began in mid-2019. Highly collaborative in nature, the project has involved the co-ordination of 20 specialist contractors with more than 50 experts on site over the last 6 months.
The interior has been fitted on three sides with gantries which frame the build stations. These have been designed and engineered to be sleek and unobtrusive, though robust enough to carry the necessary power, data and compressed air systems required to assemble the Evija.
An overhead gantry crane, multiple vehicle lifts and a wheel alignment ramp have also been installed. The interior is illuminated by more than 30,000 of the latest high-density, low-energy LEDs. A state-of-the-art light tunnel will house the rigorous final inspection, before each Evija is driven out directly onto the test track for dynamic validation.
The Evija is the first all-electric British hypercar and has a target power output of 2,000 ps, which makes it the world’s most powerful series production road car. Its ultra-lightweight carbonfibre monocoque also makes it the world’s lightest production EV hypercar, at 1,680 kgs.The engineers expect the 0 to 100 km/h time to be under 3 seconds with a top speed over 320 km/h. Running on just electrical energy with no emissions, the Evija is expected to be able to go up to 400 kms.
At long last, locally-made versions of the Proton X70 are now being released, one year and one day after it was launched in Malaysia as the first joint product of the DRB-HICOM partnership in the Malaysian carmaker.
Until today, Proton has been making the X70 in China and bringing the SUV in as a completely built-up (CBU) vehicle, just like some models of other makes from Europe and Japan. However, even though the vehicles were made in China, many parts were sent from Malaysian suppliers so even before today, Malaysian-made parts have been incorporated.
One of the reasons for using parts from Malaysia was that the X70 is a righthand drive model and the factory in China doesn’t make such a variant, so parts have not been made there. The other reason could be that the volume required was ‘small’ by the standards of vendors in China and as their supply would not be needed after a year, it was probably not worthwhile for them.
The plant in Tanjung Malim, Perak, has been in existence since 2004 but when Geely became involved, a major renovation was undertaken and a new RM1.2 billion extension was added. New manufacturing processes and equipment were also installed to raise efficiency and productivity along with quality.
Developing the vendor eco system
At the same time, Proton worked together with local and overseas vendors to establish a supply chain for parts required to build its first SUV, would be in place when production activities began. During the preparatory phase prior to start of production some months ago, Proton worked closely with its local vendors to match them with other companies who were already supplying components for the SUV.
These efforts resulted in 7 new joint-ventures being formed as both local and foreign companies started partnerships based in Malaysia to share competencies and production resources.
Other business relationships established include technical agreements and foreign direct investments, resulting in a total investment of RM263 million and the creation of 1,084 jobs as the vendor community gears up to create a pipeline of high technology components for the X70 and future models.
Production hub for RHD vehicles
“Today marks a historical milestone for Proton as we take another step towards being a global automotive brand. By producing the Proton X70 in Tanjung Malim, we have taken a quantum leap in our abilities as this is by far our most ambitious undertaking to date. This new plant will not only produce future products jointly developed with Geely but it will also be a centre for right-hand-drive production as we begin exports to countries all over world,” said Dato’ Sri Syed Faisal Albar, Proton’s Chairman, at the exclusive and private roll-out ceremony held earlier today,
An Conghui, President & CEO of Geely Auto Group, confirmed that Proton’s position within the Geely Auto Group is to be a valuable partner to grow sales in ASEAN markets.
“PROTON has undergone a tremendous transformation over the past 2 years. This experience has worked out very well for us at Geely Auto as we are happy to help Proton realize its global aspirations. We will continue to support Proton as it grows in the Malaysian market and in the wider ASEAN region and beyond,” he added.
Manufacturing technology in the Japanese auto industry has been constantly improving, enabling carmakers to deliver products that are of higher quality. Initially, the technologies were used in Japan but with the globalisation of the industry today, factories all over the planet also serve as production hubs for certain models, so they too need to have the best technologies for making their vehicles.
In view of this, Nissan will make a substantial investment in advanced technologies and equipment for its factories around the world. Following an initial investment of about 33 billion yen at the company’s Tochigi Plant in Japan, the technologies will be rolled out across factories globally.
Necessary for new generation of vehicles
These innovations will help deliver a new generation of electrified and intelligent automobiles (like the Nissan LEAF pictured above) that embody the company’s Nissan Intelligent Mobility vision, while also making production operations more flexible, efficient and sustainable. This latest investment represents a necessary rethinking of conventional car-making and tackles the structural and technical challenges of producing vehicles that will lead the industry in a new era of electrification and intelligence.
“We’re facing an unprecedented evolution in the capabilities of our vehicles,” said Hideyuki Sakamoto, Nissan’s Executive Vice-President on charge of manufacturing and supply chain management. “Our job is to make this evolution a reality by rethinking how we build cars. This will also mean shifting the efforts of our expert technicians from techniques they’ve already mastered to new, unexplored areas.”
Building the future of mobility
Nissan’s next generation of cars will be electrified, intelligent and connected. They will be ‘electronics-dense’ and use many materials which are new. This adds new complexity to design and construction, requiring major advancements in production engineering.
One such advancement is the Universal Powertrain Mounting System (shown above) developed by Nissan’s Production Engineering Research and Development Centre. Mounting powertrains in cars is a lengthy process and strenuous work for assembly line staff, who must install multiple components in sequence. Nissan’s new system uses an automated pallet to mount the entire powertrain at once.
The system measures the car’s dimensions in real time during mounting, and the pallet makes micro-adjustments accordingly. This ensures that powertrains are installed to within a small fraction of a millimetre’s accuracy. The new system is also highly adaptable. The same pallet can mount three types of powertrains (internal combustion engine, e-POWER and pure electric), and can assemble and mount 27 different powertrain module combinations.
Bringing craftsmanship to robots
Robots have the advantage of high-speed production and consistent quality, enabling faster and higher output of vehicles. However, they are not so good when there are variations and Nissan has developed certain specialist skills and processes that, until now, could only be performed by trained craftspeople. Through an intensive collaborative process, Nissan’s craftspeople and engineers have digitized parts of these delicate processes and ‘trained’ robots to perform them around the clock. This will allow the craftspeople to focus on new, unexplored areas of expertise.
Making better workplaces with robots
When robots were first used, one of the benefits was that they could do jobs that were dangerous or strenuous for humans, like welding body parts together. Robots can perform such tasks efficiently, freeing workers to perform more valuable jobs elsewhere on the line. This also improves ergonomics, making factories easier places to work.
One example is the installation of a headliner, the overhead layer of material on the inside of a car’s roof. Workers must enter each vehicle’s cabin to perform this physically demanding job. The task has become even harder as cars come with more connected features, adding to the number of devices in and around the headliners.
Nissan’s solution is to use robots to insert the headliner through the front of the vehicle and then fasten it. Sensors monitor changes in pressure and use a proprietary logic system to determine when the clips have snapped securely into place.
Lower environmental impact
Nissan is also working to reduce the environmental impact of building cars. Changes in the painting process are especially noticeable. Car bodies must usually be painted at high temperatures because the viscosity of paint is hard to control at lower temperatures. By contrast, bumpers are made of plastic, so they need to be painted at low temperatures. This requires two separate painting processes for one vehicle.
Nissan has developed a water-based paint that maintains the right viscosity at low temperatures, so that bodies and bumpers can be painted together. This will cut carbon dioxide emissions from the process by 25%. Nissan will also use a water-free painting booth that makes it possible to collect all waste paint and reuse it in other production processes.
“These new technologies and innovations are at the heart of the company’s competitiveness,” said Sakamoto. “They will be rolled out globally in the coming years, underpinning the future of Nissan Intelligent Mobility and reinforcing our status as a leader in technology.”
For nearly as long as there have been cars, people have been collecting and customizing them. Until recently, however, if owners of classic cars wanted to replace a damaged bonnet or fender on an out-of-production model, they had to search through junkyards or hire a craftsman to make a one-off replacement (which might be costly).
Now, thanks to a new technology called dual-sided die-less forming, Nissan plans to offer original specification pieces at mass-production prices. Automakers traditionally form body parts by pressing sheet metal against specially created dies. Designing and building multiple dies for each part is expensive and only pays off after stamping a large volume of parts. This is why, for locally-assembled models, many body parts are imported from a bigger plant elsewhere as the volume locally is too small to justify the investment in huge stamping machines.
This basic process has remained largely unchanged since the early days of mass production of motor vehicles. It remains a stumbling block that prevents production of low-volume parts unless costs are raised.
Nissan’s new dual-sided die-less forming technology presents a compelling alternative to the investment-intensive industry norm. It does away with dies and stamping machines altogether, removing one of the most costly and time-consuming steps in auto body manufacturing.
Owners of old models which Nissan no longer makes usually have to search at junkyards for parts. Nissan’s new technology could make it easier for them to get the parts in future.
Two robots better than one
The process involves two robots working on opposite sides of a flat sheet of metal. By syncing their movements precisely and using diamond-tipped tools developed by Nissan, the robots can shape the metal to a high degree of accuracy and detail. Working in tandem, two robots can produce intricate concave and convex shapes that could not be created if one robot were working from a single side of the sheet.
The new technique was made possible, thanks to the production engineering expertise at Nissan’s Production Engineering Research and Development Centre, along with advancements in materials technology by Nissan’s Research Division.
“About five years ago, we started thinking about ways of forming sheet metal without relying on dies,” said Keigo Oyamada, an assistant manager in Nissan’s vehicle manufacturing element engineering department, who oversaw the project. “Our goal was to solve the cost issues related to creating dies for small-volume production. We want to put this technology to use to create spare parts for old models whose dies have already been thrown away, or potentially even to let people order custom parts from Nissan.”
Performing a 3D scan of an existing part creates data that can be used to ‘teach’ the robots to build the scanned part — although some human guidance is still required. This approach will allow Nissan to produce parts that haven’t been made in decades, simply by scanning existing examples of those parts.
Custom parts – in just one week
Dual-sided die-less forming can be used to create custom body parts in less than a week, instead of waiting as long as a year for dies to be designed and manufactured. The process is also inherently adaptable; it can be used to produce small and large parts alike, as well as car parts other than body panels.
For now, Nissan plans to use dual-sided die-less forming to produce replacement parts for cars the company no longer sells. Looking further ahead, the company sees potential for creating customized parts for those who are looking to add a little uniqueness to their future rides.
For assistance in obtaining Nissan Genuine Parts in Malaysia, visit www.tceas.com.my.
Hyundai Motor Company has signed a Memorandum of Understanding (MOU) with the government of Indonesia to build its very first manufacturing plant in the country. Why Indonesia? Hyundai sees the country as a potential growth into the ASEAN markets as well as securing future growth engines in the global automotive market. (more…)
Nissan Spain understands that when it comes to its production line, the physical wellbeing of their staff is one of their major priorities. To ensure that they get all the help they need in order to be safe, healthy, and productive, they’ve come up with a revolutionary method; exoskeleton devices. (more…)
Perhaps you may not have realised it but many years after a model has ceased to be produced, genuine parts from the manufacturer are still available from its own service centres or authorised parts stockists. Some may be surplus stock but there will also be many parts that continue to be made after production of the model (or generation) had stopped. This ensures that subsequent owners of the model can still get genuine parts which are made to the same high quality standards as when the model was still in production.
It’s a sort of ‘unwritten’ industry practice that parts for a model will continue to be available from the manufacturer for at least 10 years after the end of production. For a market leader like Perodua, which has been producing cars since 1994 and put over 3.7 million vehicles on Malaysian roads, there’s a major responsibility to ensure that the parts remain available. This is especially so in Malaysia where there is still no ‘end-of-life’ policy so cars tend to be used for a long time.
Since 1994, Perodua has put over 3.7 million vehicles on Malaysian roads and many are still running.
One-third of parts demand for old models
Currently, a third of the demand for Perodua parts is for past models such as the first-generation Myvi, Viva, Kelisa and even the Kancil. Besides making the parts at its own factory complex, Perodua has also assigned some parts to Industrial Quality Management (IQM) Sdn Bhd, its supplier since 2002. IQM currently supplies metal stamping, body assembly parts and brake tube components to Perodua. It also began making Viva parts when production of the model ended in 2014 and last year. it began making parts for the second-generation Myvi on a dedicated new line.
Today, Perodua announced that it is centralising parts production for its past models with the launch of a new press stamping machine at its facility within IQM’s factory located in Tanjung Malim, Perak. The move is one of Perodua’s many initiatives with its suppliers to help expand their business and capabilities, bringing them one step closer to becoming global automotive suppliers.
The IQM factory in Tanjung Malim, Perak
Freeing up space and simplifying operations
At the same time, this frees up much-needed space in Perodua’s complex, simplifies the entire operation, reduces lead time and cost, and makes it easier to monitor under one roof. Perodua also assists IQM in terms of skill transfer and training where past model parts production is concerned.
A RM7 million investment on the machine, including its transportation and installation, was made by Perodua entirely. The 1,600-metric tonne hydraulic press stamping machine will produce body parts such as bonnets, side outer panels, rear quarter panels, fenders, doors and roofs for past Perodua models. The dies required to make the past model parts have also been moved to IQM.
The parts made by IQM for the Perodua Viva since 2014.Dies for body panels to be produced with the new press stamping machine which required an investment of RM7 million.
Supporting owners of past models
“Perodua’s decision to centralise past model parts production at IQM is 4-pronged. One, we want to continue supporting owners of our past models with quality, quick and affordable parts through our Body & Paint business, because as long as you own a Perodua vehicle – old or new – we will always be there for you,” said Perodua’s President & CEO, Dato’ Zainal Abidin Ahmad.
“Two, we are committed to empowering all 135 of our Malaysian suppliers, not just by buying from them but helping to develop them via skill and technology transfers. Three, it represents our commitment to the nation and its economy by helping to boost the competitiveness of the Malaysian automotive eco-system,” he added. “Finally, it represents our commitment to ourselves. To keep improving our quality and efficiency so that Perodua can be a better and leaner company moving forward,”
Old models undergoing repairs at a Body & Paint facility after an accident may require body parts which must be properly manufactured to ensure safety and strength.
With all its current models having over 90% of parts purchased locally, Perodua is naturally the biggest buyer of automotive components in the country. It has spent RM4.5 billion on parts so far this year out of a planned RM5.4 billion for the whole of 2019.
Visit www.perodua.com.my to locate a service centre where you can purchase Perodua Genuine Parts.
Having received its World Manufacturer Identifier (WMI) that makes it a recognised vehicle manufacturer, Polestar is set to accelerate ahead at its first production facility located in Chengdu, China. This new Polestar Production Centre sets a new industry benchmark in electric vehicle manufacture and will produce the Polestar 1 – an exclusive, carbonfibre-bodied Electric Performance Hybrid.
500 Polestar 1 cars are to be built per year, with a total of 1,500 planned over a 3-year production cycle. Construction of Polestar 1 in Chengdu will be followed by production of the fully electric Polestar 2 in Luqiao, China, in early 2020.
Most premium new energy vehicle
The new facility, which was completed on schedule, will produce cars for both China and global export markets with first customer deliveries expected before the end of 2019. The company presents the Polestar 1 as ‘the most premium new energy vehicle to be manufactured in China’. Included in the manufacturing process is a team of highly trained quality control auditors whom, with a minimum of 10 years of experience, apply some of the strictest monitoring and assessment procedures in the industry.
The Polestar Production Centre aims to be one of the most environmentally responsible car factories in China. Designed by internationally renowned architecture and design company, Snøhetta, the new production facility incorporates a customer experience centre including a test track and a glazed atrium offering a panoramic view over the factory floor.
New standards in manufacturing
“Designing Polestar’s first production facility has been a challenging and extremely rewarding project for us,” said Snøhetta’s co-founder, Kjetil Trædal Thorsen. “The innovative design of the interaction scheme aligns creative visionary processes with technical production requirements, setting a new standard for inclusive fabrication facilities.”
“We promised we would have our first production facility built in 2019; we promised cars would be delivered to customers this year, and we promised we would do things differently – once again, we are delivering on our promises. This is a hugely proud moment for the whole team at Polestar,” said Thomas Ingenlath, CEO of Polestar.
The increased automation, particularly the use of robots, is feared to reduce the number of humans needed to do work in factories. It has a lot of implications and companies are trying to find a balance in their workforce. However, humans are still needed for some types of assembly work, especially where it involves variations. Robots work more efficiently when the work is constantly similar (eg welding bodies) so customisation of specifications is harder to programme.
Therefore there will still be a need for humans in the factory and the dream of the former General Motors CEO, Roger Smith, of a factory with no humans at all, building cars non-stop all day long will likely remain just a dream for some time to come.
Long hours in difficult environments
Though the work humans will do will be suited for them physically and less dangerous, they may still spend long hours working in difficult environments. To reduce fatigue, the Hyundai Motor Group (HMG) has developed a Vest EXoskeleton (VEX) which is a wearable robot to assist them.
The VEX helps by imitating the movement of human joints to boost load support and mobility. The wearable vest the polycentric axis – combining multiple pivot points with multi-link muscular assistance – to function, eliminating the need for a battery.
Attached like a backpack
At 2.5 kgs, it weighs 22 – 42% less than competing products and is worn like a backpack. The worker places his or her arms through the shoulder straps of the vest, then fastens the chest and waist buckles. The back section can adjust in length by up to 18 cm to fit a variety of body sizes, while the degree of force assistance can be adjusted over 6 levels – up to as much as 5.5 kgf.
“VEX gives workers greater load support, mobility, and adaptability when operating in overhead environments,” said DongJin Hyun, Head of Robotics team of HMG. “Workers will also appreciate how light VEX is to wear and work with.”
The newly-developed product is targeted at production-line workers whose job is primarily overhead, such as those working on the underside of vehicles – fitting brake tubes, attaching exhaust systems, etc.
Already used in 2 US plants
The development of the VEX included a pilot program in two HMG plants in the USA. The trial was widely successful in assisting workers and boosting productivity and both plants have incorporated VEX systems in their production lines.
One of the two Hyundai Motor Group factories in the USA where the VEX is already assisting workers.
The Group is considering introducing the VEX in plants around the world. It is expected to go into commercial production in December and is projected to cost as much as 30% lower than existing products which usually costs around US$5,000 (about RM21,000).
Growing demand for wearable robots
According to the International Federation of Robotics, the wearable robotics industry is growing 14% annually, a rate which is accelerating. By 2021, approximately 630,000 commercial robots will be sold worldwide, with the greatest demand coming from the automotive sector. Recognizing the market trend, HMG is making active investments and strengthening its presence within the growing robotics industry by securing relevant technologies.
Weight has long been known as something that must be reduced as much as possible in a car. Lowering the weight brings benefits to fuel efficiency and handling, two important aspects that engineers keep trying to improve all the time. However, back in the days before computer-aided engineering (CAD), it was difficult to achieve weigh reductions and manufacturing technology then was also not able to handle advanced steel materials.
The advent of high-tensile steel was a big leap forward for the auto industry. This type of steel has high strength but the greater strength does not require extra weight. In fact, compared to conventional steel, high-tensile steel is lighter yet stronger.
Stronger steel produces a number of clear benefits for the customer. The overall weight reduction improves fuel economy, while the increased strength builds on existing safety. Since the steel is stronger, the sections become smaller and more interior space is available, producing environments that are more open for the driver and passengers.
Use of advanced high-tensile steel gets award
When creating the latest QX50, engineers at Infiniti, Nissan’s premium brand, went into molecular detail to ensure it was the best it could be in every aspect, and the science behind a more advanced high-tensile steel used in the QX50 has just received a prestigious global award.
One of the challenges of very high-tensile steel is it can be difficult to work with in the manufacturing process, limiting the complexity of parts and adoption in a new vehicle. In order to make this world’s first steel compatible for mass production, engineers worked directly with a steel supplier to formulate a brand new, high-strength, lightweight and highly formable steel for the model.
980 MPa steel supersedes 590 MPa steel
The new 980 MPa steel, created using a specially developed formula, has superseded the traditional 590 MPa steel. As part of the work around the new steel, an academic paper on ‘The application of 980 MPa advanced high strength steel with high formability’ was chosen for The SAE/AISI Sydney H. Melbourne Award for Excellence in the Advancement of Automotive Steel Sheet. It is awarded by SAE International, a global nonprofit organization based in the USA, which has more than 128,000 participating engineers and researchers working in aerospace, passenger car and commercial vehicle industries.
Around 27% of the QX50 body is made from special steels – an increase of 21% over the previous generation – resulting in a 23 kg mass reduction overall. Within the front of the car alone, the adoption of high-tensile steel has provided a 13 kg weight reduction, while frontal energy absorption improved by 10%.
With the QX50 being the first car in the world to use 980 MPa steel, Infiniti will look into adopting it in more applications in coming years. The goal is to achieve 25% or more of the vehicle weight made from advanced high-strength steel, benefiting customers with reduced weight, improved fuel economy and enhanced levels of safety.
Visit www.infiniti.com.my to know more about the models available in Malaysia.
