Three complete power press production lines provide higher availability, shorter cycle times and ease of service to produce thermal and acoustical protective heat shields for automotive engines.

Dana increases speed with complete solution from AP and T Dana Corporation's purchase of three complete production lines from AP and T has provided the advantages that the company was looking for: Higher availability, shorter cycle times and ease of service. Three complete AP and T production lines are in operation in Dana's Chatham, Ontario production facility. In Chatham, Dana produces thermal and acoustical protective heat shields for automotive engines.

The three lines include a total of 17 presses and are used in the fully automated production of thermal heat shields.

Dana also utilises AP and T equipment at other production facilities.

When Dana was ready to invest in a new line at Chatham, they chose AP and T as their partner.

The choice was based on a number of factors, including visits to other companies where AP and T equipment had been installed.

'A technical advantage that AP and T offered was a completely integrated system that is engineered and programmed as a single system.

Many of their competitors purchase many of the major components and alter their system programming to accommodate them,' said Jim Westover, production manager at Dana's Chatham plant.

After the first line was installed, Dana decided to install two almost identical additional lines from AP and T, in order to meet increased demand.

* Lines with five and six presses - in each of the three lines, Dana produces five to ten different thermal heat shields.

Two of them use six presses; the third uses five presses.

The processes are similar for all of the lines.

As an example, the production process of one of the six-press lines looks like this: AP and T's ZL style hydraulic presses are used in the lines with press forces ranging from 1000 to 2000kN (100 to 200 tonf) .

Material is fed into the first press by a coil feeder.

The press cuts a blank and makes a fold.

If required, holes are punched here as well.

The detail is then transferred to the second press by a monobar transfer feeder, the MB80, which is mounted directly on the press.

The MB80 is virtually maintenance free and is part of the newly developed sixth generation of AP and T automation equipment.

In the second press, an additional coil feeder feeds both metal and insulation filler.

All three layers of material are cut in the press.

Two transporters are used to remove the metal and filler scrap materials.

In the third press, the detail is folded together.

To ensure the quality of the end product, a detector checks that insulation material is placed between the two metal sheets.

In press four, the layers are pressed together and if needed, holes are punched.

The fifth press gives the detail its final shape using deep-drawing technology.

The detail is then lifted by an ABB robot and placed in press six, where holes are punched.

A second ABB robot lifts the detail out of the line for control and transportation.

In the five-press line, an additional process is added after the line.

The process is a free-standing welding and riveting work station, that can run with the AP and T line as one complete system.

It can also be disconnected and parts can be produced directly from the press line.

* Value for your dollar more important - for Dana, the new investments mean increased uptime, quality and reliability.

'As with most companies, price is very important; but more important is value for your dollar.

AP and T was not the lowest bidder, but they were able to convince us that they could supply better value through quality and therefore increased uptime,' said Westover.

'A sign of this is the improved cycle time.

The cycle time on the AP and T line is approximately 10% better than similar lines we have.

But more importantly, the AP and T line does not appear to be stressing the presses or the transfer system to attain these times.

We feel this will give us more hours of operation without problems,' said Westover.

* By far the quickest system - another important factor contributing to the higher availability is the semi-automatic tool change system.

'This tool change system is by far the quickest and least physical system we have.

Changeovers are completed in much less time than on other comparable lines.

It is particularly nice having the computer sequence the functions as this ensures nothing is missed and everything is performed in the most logical order,' said Westover.

Overall, Westover is very satisfied with AP and T's products and performance as a supplier.

'AP and T is the first company we have contracted that has fulfilled their commitment and supplied what was promised as scheduled,' said Westover.

* About Dana Corporation - Dana Corporation is a leading global supplier of axle, driveshaft, engine, frame, chassis and transmission technologies.

The company is based in Toledo, Ohio and reported sales of $9.1 billion in 2004.

Dana employs 46,000 people in 28 countries.

The Chatham, Ontario production facility is part of Dana's automotive division.