Successful at our customers!

What will urban mobility look like in the future?

The Upgrader- The concept vehicle of the Schnitzer Group

Climate protection and the reduction of CO2 emissions will significantly determine the future of urban infrastructure. For individual electromobility, lightweight construction concepts that take the circular economy into account are also required. With the approach project, technology, quality Stefan Mangold develops the Schnitzer Group's first own vehicle concept in the team, the "Upgrader". The aim is to design concepts for urban mobility and test them in terms of functionality and comfort. The vehicle, which is designed in lightweight aluminum, is intended to provide a range of at least 130km while weighing less than 50kg. The first test drives will start this spring. We will keep you informed about the progress and the process of the tests.

Optimization of the injection molding process for a rear trim at an Austrian automotive supplier

Problem: audit still revealed visual irregularities on the surface of the rear trim
Cause: optimization potential of the injection molding process not yet fully exploited
Solution: generation of a stable and series-production-capable injection molding process with the approach of a 0-defect strategy

Procedure:

• Performance of filling studies and a DOE (design of experiment).
• Analysis of the existing injection molding process and evaluation of the defect characteristics for the rear trim
• Planning of the strategy and procedure for 0-defect components with the supplier

Measures for process optimization were derived from this:

• Improvement and mold deaeration tailored to the article requirements
• Optimization of the filling and closing times at the hot runner to achieve the best possible sequential filling
• Optimization of injection speeds
• Adjustment of melt temperatures
• Optimization of the holding pressure profile

Technical project management with a holistic approach is our focus. We want to offer customers effective added value. We achieve this with our SYSTEMIC Upgrade. In this project, the current q-status of the component with its deviations was technically analyzed, discussed and a targeted optimization strategy with the goal of "0-defect components" was developed using the practiced swarm intelligence and hands-on experience of the Schnitzer-colleagues Tutsch, Wörrlein, Rössler in Weissenburg. Gernot Tutsch, project manager, had the task of coordinating the strategy and approach with the customer and supplier. (One-Face-to-the-Customer Principle). In the background he had his two technology experts respectively for injection molding and tool technology. Over several steps, several appointments, also with the sub-supplier and in close coordination with their specialist departments, the process was optimized for the production of defect-free components. An important component here was the partnership-based cooperation with the experts and teams at the customer and sub-supplier. Process-accompanying evaluations of the component and process quality for the definition of the further procedure could be worked out constructively on site in the team. With professional communication to the customer and a targeted and differentiated flow of information to all stakeholders, project manager Tutsch succeeded in informing, motivating and keeping the project team together in the best possible way.

We are able to follow and check even complex processes in a highly technologized production from incoming goods to the finished component "step by step" by means of video live meetings. What was unthinkable just a short time ago has almost become the new normality in just a few months. The trend is moving in one direction - Industry 4.0! This is associated with the digitalization of processes, workflows and also communication channels for the joint exchange of information. Of course, automotive-compliant test and audit methods form the basis for a virtual process inspection. How to prepare this in detail and transfer it to the current situation is already actively lived by our colleague Patrick Heine in daily practice. In his current project, the manufacturing process of a rear spoiler drive unit is being examined from the delivered individual parts to the fully assembled, tested and finally shippable end product. In addition to manufacturing with a wide variety of components, pre-assemblies and the use of diverse materials, it is above all the requirements on the components that make this complex here. "Good preparation with an agenda, issues to be clarified from the ongoing project and the overarching audit program are the focus," says the ambitious project engineer. In this context, the virtual environment and the internet connection must be stable in terms of image and sound. With the technical features, this forms an important prerequisite, which otherwise massively disturbs. Also, the project team should really be available on the scheduled date. What, when and above all how will be filmed? Then there is the question of whether proactive explanations will be given on site and how flexible are the employees? What, when and above all how will be filmed? Then there is the question of whether proactive explanations will be given on site and how flexible are the employees? The feeling and transparency of a live on-site visit must be achieved online. This is how a virtual production and process approval can also become a success.” In this project assignment, colleague Heine examined the topic of production capability from the supplier side. Very often we are also booked by the customer (OEM) for this task. No matter from which point of view, we accompany initiatively on highest IT standard, neutral and with high technical competence.

Quality audit, proof of production capability, fault analysis, sampling, tool and process optimization - carried out virtually with MS teams, VR cameras, high-resolution images and videos is now part of the Schnitzer Group team's standard repertoire. However, for the evaluation of complex, technical contexts, virtual communication reaches its limits. The perception of being live on site, immersing in technical processes with all available senses, talking to people directly on the assembly line or a production plant and developing solutions cannot be replaced by remote. Due to the current travel restrictions and closed borders, the Schnitzer Group has enabled external colleagues worldwide to visit suppliers in the usual quality, live and to advance projects on site. The main focus is on Germany; Italy; Austria, Czech Republic, Slovenia, Slovakia, Poland, Croatia, Portugal; Spain; Turkey; Switzerland; China; USA; India....

Quality requirements are becoming increasingly multilayered, even for experienced suppliers. When new companies recognize markets they think might be lucrative, they often push their way into those markets and start winning projects without truly understanding the quality standards. Schnitzer Group guides these new partners, as well as experienced suppliers, through the “jungle of sampling“ by offering requirements-based and individualized training sessions/workshops and practical overviews/charts that make the approval process transparent. The teams provide strategic and operational support for sampling throughout the entire product development process. Whether OEM, TIER 1, mold makers or material suppliers – the Schnitzer Group Team‘s favorite color is green.

Developed in Europe – produced worldwide. In global production, it is important that the defined serial production processes are adhered to at all locations around the world. This does not always happen. An OEM hired Schnitzer Group to handle implementation of the European automobile standard in China and the process requirements of the European OEM among the Asian suppliers. In another project, Schnitzer Group worked with the specialist departments of a TIER 1 company to moderate the knowledge transfer of new processes from the European development location to the global production locations of the TIER 1. Incidentally, this project also helped the TIER 1 company improve its intercultural cooperation and communication. Schnitzer Group speaks the language of your industry.

A new supplier appears to be highly promising for an extensive development project and everything they offer is appealing. This makes the purchasing decision a no-brainer. The development process makes rapid progress at first. Technical and design modifications are implemented by the supplier without resistance. However, during the industrialization of the project, the situation starts to look a little different. The supplier specializes in small serial productions and has neither the experience nor the resources to handle a large serial production project. The problems are multilayered and complex. Ultimately, the relocation of the project to a new supplier was the only path to secure the start of production of the vehicle. Schnitzer Group was heavily involved in the task force, both on the organizational side and the technical side.

The TIER 1 company for exterior plastic parts had been well positioned. Because it covers everything from moldmaking, to injection molding, to plastic injection molding production and final painting, the TIER 1 company was able to acquire many new orders – too many, as it turned out in the course of day-to-day operations. Here, Schnitzer Group provided successful support in multiple projects. Directly commissioned by TIER 1, Schnitzer Group was responsible for comprehensive project-leadership in subprojects for the sampling processes as well as for mold validation and process optimization at the various locations. Critical factors for making this project a success included excellent networking among the Schnitzer SYSTEMIC project managers, technical expertise and practical communication with all project stakeholders.