light weight parts and chemical management in …¼“）(asada) pw181105bsef_asia...’94 celica...

Light weight parts and chemical management in auto industry

2018.11.05 Satoshi Asada

TOYOTA MOTOR CORPORATION

BSEF Aiea Forum 2018

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1. JAMA organization 2. CO2 challenge for Auto sector 3. New plastics parts application 4. Supply chain management system in Auto sector & collaborations with Chemicals 5. Expectations to the Chemicals

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14 companies (Passenger, Truck & Bus, Motorcycle )

JAMA member companies BSEF Aiea Forum 2018

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JAMA Committee Organization BSEF Aiea Forum 2018

Board of Directors

Executive Committee

Environment Committee

Factory Environment S/C

Chemical Substance Management S/C

Environment Issues S/C

Recycling & Waste Reduction S/C

・Regulatory trend monitoring ・Vehicle Indoor Air Quality ・Collaborate oversea w/auto sector （GADSL, AI-REACH TF etc.）・Windows to other industries ・Windows to the JPN Government


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TOYOTA Environmental Challenge 2050

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6-Challenges



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Engine powered Vehicle

2020 2050 2010

HV PHV

FCV EV

①New vehicle zero CO2 emissions challenge ～▲90% by 2050 compared to 2010～



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② Life Cycle Zero CO2

TOYOTA



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CO2 trend for vehicle

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Korea EU 67

China 75

Saudi Arabia Australia

Taiwan Brazil

Mexico ① Power train efficiency ② Vehicle aero performance ③ Weight reduction

50% Reduction

Material composition trends

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Steel

Plastics

1968 (1020kg)

1978 (1144kg)

1988 (1300kg)

1996 (1313kg)

2000 (1371kg)

2011 (1471kg) Lexus IS

Mark II

Nonferrous metal Glass

Rubber

Others

Slim up !! philosophy

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・Even now, “Steel” is the major component in automobile So, “Weight reduction” for “Steel” is the main measure. -> Use “High-tensile steel” as much as possible -> Precis control “Steel plate thickness” as parts shape -> Partial optimization for “Material Strength” -> Optimizing “Material joining” methods

・Aluminum（Hood Cover, Chases part, Body part etc.）・Magnesium（Similar application for Aluminum）・Plastics（External panel etc.；Recycle, Flame retardant etc.）

１．”Steel” weight reduction as much as possible

２．Utilizing “Light weight materials”


https://www.google.co.jp/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=2ahUKEwiNx6SBjqDdAhUDU7wKHe4mAocQjRx6BAgBEAU&url=https://www.crecla-minami.jp/blog/%E3%83%A1%E3%82%BF%E3%83%9C%E3%83%AA%E3%83%83%E3%82%AF%E7%97%87%E5%80%99%E7%BE%A4%E3%80%80%EF%BD%9E%E3%82%AF%E3%83%AA%E3%82%AF%E3%83%A9%E6%B0%B4%E3%80%85%E3%82%88%E3%82%8A%E6%83%85%E5%A0%B1%E3%80%80vo/&psig=AOvVaw0E5gx7jAu6zBgWybFYWe8n&ust=1536107889947781



Light weight material trend

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’ ００ ’ ９５

’93 SUPRA HOOD ’01 SC430 HOOD, ROOF BACK WINDOW FRAME

’06 LS600h/460 HOOD

’09 SAI HOOD ’11 CT HOOD LIFTGATE

’ ０５ ’ １０

’11 Prius α HOOD

’ ９0

‘94 RAV4 ROOF

’94 CELICA GT4 HOOD

Steering Wheel Core

Steering Column Jacket

Air Bag Housing

Brake Pedal BRKT

Engine Head Cover

Seat Frame

’ 15

’10 LFA Cabin

’15 MIRAI Stack flame


“Cost”, “Performance”, ”Mass Productivity”, & “Necessity”

http://trendy.nikkeibp.co.jp/article/special/20091021/1029743/?SS=expand-life&FD=1136892796

Adoption trend C-FRP parts

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FCタンク


CFRP Roof

CFRP Spoiler

CFRP hood

CFRP hood CFRP Roof

CFRP Rear wing

CFRP Backdoor

CFRP Side-door Luggage Roof

Thermoplastic CFRP FC stack flame FC hydrogen tank

Core technology was developed In Lexus LFA & spreading Application.

Fuel Cell vehicle “MIRAI” C-FRP parts

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FC stack flame Hydrogen tank

・Significant weight reduction modify the structure

Worldwide first auto application Thermoplastic CFRP part

MIRAI

Thermoplastic CFRP sheet


C-FRP Hydrogen tank

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■Specification

Pressure 70 MPa

Volume 122.4 L（60.0 L+62.4 L）

H2 storage 5.0 kg

CF-Prepreg

Base

Cylindrical section

Dome section

Boundary section

Plastic Liner (Seals in H2) CF reinforced plastics (Pressure resistance)

GF reinforced plastics (Surface protection)

Dome section

Cylindrical section

Boundary section Liner

Helical winding

High angle Helical winding Hoop winding


Prius-PHV back-door

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-Weight reduction 40% weight reduction compared with Aluminum -Design flexibility Double bubble shape (aerodynamic) Better visibility

C-FRP （C-SMC）

TSOP

38.3°for Prius

40°for Prius-PHV

Lexus LC500 coupe

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V-8 5.0L 477PS 2WD（FR）

Vehicle weight：1.940kg

Lexus LC500 C-FRP parts

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CFRP Door inner

CFRP Roof

CFRP Luggage inner


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Complexity & parts number

21 Body component

Assembly pats : 2,000 – 3,000 / vehicle

Body : 1 Engine : 1 Transmission : 1

Engine component

Transmission component

Component parts: 50,000 and more / vehicle

Complexity parts structure & Number!!

TOYOTA


http://www.jfe-holdings.co.jp/archives/nkk_360/No.52/img/52-02b.jpg

http://www.shima-corp.co.jp/kokunai/list/images/itemlist/engine_01.jpg

http://www.h-ion.com/cpm/set/enjinvh4501.jpg

http://www.hachiman-th.ed.jp/yamadate/piston.jpg

http://images.google.com/url?q=http://www.car-market.jp/maintenance/check/img/automatic.jpg

http://www.trust-power.com/02greddy/others/power_system.JPG

http://www.kuwana.ne.jp/hkr/photo/products/pro4/p4_photo1.jpg

http://www.google.co.jp/url?url=http://jp.autoblog.com/2014/05/11/lexus-rc-f-orange-name-color/&rct=j&frm=1&q=&esrc=s&sa=U&ved=0ahUKEwitr6LNwf3KAhUjFqYKHR0vDLs4UBDBbggoMAk&usg=AFQjCNEfqY_bLk9UVSpMNZ4g-bhzDSow-Q

Automotive supply structure

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Auto-OEM （JAMA, ACEA, USA）

Tier1 Tier1

Auto OEM

Metal （Steel, Nonferrous）

Chemical (Plastics, Paint Adhesive, Fluid Rubber etc.） Electric & Inorganic materials

Tier2 Tier2

Tier3 Tier3 Tier3 Tier3

TierN TierN TierN TierN

Tier2

TierN

Part suppliers （JAPIA, CLEPA etc.）

One Auto-OEM Have 3,000 Tier1 suppliers

Complexity of auto supply chain

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Tier 1

Tier 2

Tier 3

Tier N

Oversea supplier Domestic supplier

(1,500)

(750,000)

(Overseas, law material / article )

TOYOTA


http://www.google.co.jp/url?url=http://jp.autoblog.com/2014/05/11/lexus-rc-f-orange-name-color/&rct=j&frm=1&q=&esrc=s&sa=U&ved=0ahUKEwitr6LNwf3KAhUjFqYKHR0vDLs4UBDBbggoMAk&usg=AFQjCNEfqY_bLk9UVSpMNZ4g-bhzDSow-Q

Green Purchasing Guideline

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https://www.toyotaglobal.com/sustainability/environment/management/green/pdf/TOYOTA_Green_Purchasing_Guidelines_2016_en.pdf

IMDS/GADSL collaborations

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Material data (not only materials info.) -Parts info.

-Supplier info.

-Base material info.

-Hazardous substance info.

Data format & rule

GADSL: Global Automotive Declaration Substance List

Data collection system & archive

IMDS : International Material Data System

Substance list

TOYOTA


Outline of IMDS

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What is IMDS? A common platform for collecting/analysing components/material information in the automotive industry.

• An environmental information communication system that 8 European OEMs (Audi, BMW, Daimler Chrysler, Ford, Opel, Porsche, Volkswagen, Volvo) have led development.

• Operated by major OEMs in Asia/US/EU with cost contribution. (6,000,000 euro/year) • A system accessible through an internet. • Suppliers can use the system free of charge. • The system will be available immediately after online registration. • Almost de facto standard in automotive industry for data collection.

TOYOTA


Structure of IMDS

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OEM Tier1 Tier2 Material maker

MDS request for assy

MDS request for component

MDS request for material

MDS data for assy

MDS data for component

MDS data for material

IMDS data flow

TOYOTA


IMDS data center (former HP)

IMDS adopting auto-OEM

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2000 2002 2004 2006 2008 2010

Auto OEM Membership trend

Participating OEMs : over 30 Participating Suppliers: 168,626 Registered users: 464,725 people (as of April 2018)

TOYOTA


http://www.daimler.com/dccom

http://www.chrysler-japan.com/index.html

Current status IMDS data

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Approximately 168,626 companies, 69,644,0079data (as of Apr. 2018)

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

35,000,000

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

100,000

IMDS registered data amount IMDS registered companies IMDS registered companies and data amount

IMDS登録企業数 IMDS登録データ数 IMDS registered companies

IMDS registered data amount

TOYOTA


IMDS/GADSL collaborations

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Material data (not only materials info.) -Parts info.

-Supplier info.

-Base material info.

-Hazardous substance info.

Data format & rule

GADSL: Global Automotive Declaration Substance List

Data collection system & archive

IMDS : International Material Data System

Substance list

TOYOTA


Outline of GADSL

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Global Automotive Declarable Substance List

<Remark> ・First GADSL is issued in 2005 and revised every year. ・2018 GADSL issued Feb. 1st 2018 ・The official GADSL will be the current English version as posted on the GADSL website: http://www.gadsl.org.

TOYOTA


GADSL pre-view

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Classification P: Prohibited D: Declarable

Reason code LR: Legally Regulated FA: For Assessment FI: For Information

Source EU: REACH, Member states law etc. USA: TSCA, State law CANADA: CPCYS, CANADA Challenge Japan: Chemical Substance Control Law UN: POPs, Monitorial treaty

229: Substance Group 3284: Substances

TOYOTA


GASG collaborations

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Global Automotive Stakeholder Group GASG Steering Committee

Members of automotive, supplier, chemical industries

Coordination Team

Auto OEM Suppliers

ACC （American Chemistry Council）

Auto OEM

JAPIA JCIA

（Japan Chemical Industry Association)

Auto OEM

CLEPA (European Association of

Automotive Suppliers) Cefic

(European Chemical Industry Council)

GADSL is managed by the Global Automotive Stakeholder Group. GASG is a voluntary organization of the Automotive Supply Chain.

TOYOTA



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Expectations to the Chemical Industry

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- Collaborate with supply chain for the information exchange + Detail substance information + Detail mixture information + Equivalent criteria for “Classification”

- Close communication for the chemical regulation + Regulatory trend + Handling of regulated substances & alternatives ( Auto industry needs to allow a significant lead-time for the evaluation & to commit to supply legacy spare parts)

- Maintain the “ hot line” among Chemical & Auto industry

TOYOTA


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light weight parts and chemical management in …¼“）(asada) pw181105bsef_asia...’94 celica...

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