One-Shot® A Pillar Bicolor
Here is the method that allows you to make a bicolor pillar in two different colors, in just 70 seconds and in a single process
We guarantee you:
- The creation of the component in a single phase and in a single production cell
- A cycle time of 70 seconds
- A lighter monolithic piece
Why is this methodology so revolutionary?
WITH THE TRADITIONAL METHODOLOGY
the components are made in two moulds, with two machines, one of 100 tons and the other of 300 tons and two operators in charge of the presses. Another man takes care of joining the two pieces, through the ultrasonic welding machine.
PROBLEM
this part of the traditional process is still manual and affects component costs and lead times.
WITH THE TRADITIONAL METHODOLOGY
the coupling of the components takes place mechanically: produced separately, they are then placed one on top of the other.
PROBLEM
this could cause coupling problems during assembly and small aesthetic imperfections, which may be visible to the outside eye.
WITH THE TRADITIONAL METHODOLOGY
it is necessary to superimpose the two components and create pegs which are then dissolved.
PROBLEM
The monolithic piece turns out to be very heavy. It is a procedure that creates a component that is not aligned with the Horizon 2020 standards.
Thus was born the revolutionary One-Shot® process!
One day, however, a group of engineers within sapa began to gather to find a solution to these problems, in a top-secret department called "Innovation Engineering"
3 moulds, dependence on external suppliers, 2 processes (moulding + injection). become:
- 1 job only
- 1 component only
- 1 single press stroke In a single production cell
And the "pleasant consequences" are many:
- your components will be lighter, improving the dynamics and stability of the car;
- in just 70 seconds the component is finished saving you time on production.
- the monolith does not require manual assembly, thus reducing the production of waste and - consequently - the environmental impact.
Summing up
Traditional method
- Using 2 presses
- Use of mold + ultra sound welding machine
- Non-automated process
- It is necessary to superimpose the two components and create pegs which are then dissolved =+ weight
- 2 specialized press operators +1 specialized welding machine operator
One-Shot® method
- 1 press
- 1 mold only
- No pegs = -weight
- Robotic process
But it doesn't end there
The One-Shot® bicolor pillar has already been industrialized and mounted by Jeep on the Renegade model, but the same procedure can also be replicated on other models.
FCA-Supplier of the year 2018
In 2018, the prestigious FCA Supplier of the Year award went to SAPA.
LANDING - A Pillar Bicolor EN
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