Dana Corporation Demonstrates Manufacturing Flexibility with Toyota Tundra Frame
14 November 2003 - 5:35AM
PR Newswire (US)
Dana Corporation Demonstrates Manufacturing Flexibility with Toyota
Tundra Frame TOLEDO, Ohio, Nov. 13 /PRNewswire-FirstCall/ -- Dana
Corporation's Owensboro, Ky., facility has demonstrated its
flexibility by implementing a lean assembly process to manufacture
an extended frame for the all-new Toyota Tundra Double Cab pickup.
Toyota selected Dana to supply a frame that is more than a foot
longer than standard frames for the longest and widest version of
the Toyota Tundra. (Logo:
http://www.newscom.com/cgi-bin/prnh/19990903/DANA ) The pickup
truck, available this fall, is more than 230 inches long from
front-to-back. The extra length of the frame was achieved by
designing the regular tooling to accept the additional length of
the new side rails. The assembly process incorporated automatic
changeovers to continue the lot-size-of-one capability. The design
also incorporates additional reinforcements for strength and
performance. Dana people worked on one part of the frame at a time
beginning with the rear stub, where the frame required the most
significant changes. "In a little over a year's time and without
disrupting current production, we were able to reconfigure our
manufacturing process to accommodate a frame that is more than 5
percent longer than the current version," said Bill Carroll,
president of Dana's Automotive Systems Group. "This is truly a
great success story for our customer and Dana alike, and showcases
our manufacturing flexibility." When faced with the challenge of
producing the extended truck frame efficiently and within a tight
deadline, Dana integrated improved manufacturing processes within
current production space. Working closely with Toyota, Dana
engineers implemented 14 new assembly cells piece by piece,
resulting in a seamless transition at the start of production. In
addition, the Tundra program team incorporated new automated
processes that accomplish more tasks in less space. One example is
a new automated welding cell that simultaneously welds three frames
in the space previously required to weld just one. It takes just
over one minute for the team members at Dana to produce a complete
frame. Continuing the Owensboro plant's drive for flexibility,
production rates can be reduced or increased to continue
just-in-time sequential delivery under varying market demands.
"This is a great example of how Dana works with customers to
manufacture specialized, high-quality products efficiently," Mr.
Carroll added. "Employees from every level of the organization
worked together to make the launch successful, meeting Toyota's
high expectations." Dana's Owensboro plant manufactures frames for
all Tundra pickups and Sequoia sport-utility vehicles and employs
approximately 330 people. Dana has been producing frames for Toyota
for more than 10 years. Dana Corporation is a global leader in the
design, engineering, and manufacture of value-added products and
systems for automotive, commercial, and off-highway vehicle
manufacturers and their related aftermarkets. The company employs
approximately 60,000 people worldwide. Founded in 1904 and based in
Toledo, Ohio, Dana operates hundreds of technology, manufacturing,
and customer service facilities in 30 countries. The company
reported sales of $9.5 billion in 2002. Dana's Internet address is
http://www.dana.com/ .
http://www.newscom.com/cgi-bin/prnh/19990903/DANA
http://photoarchive.ap.org/ DATASOURCE: Dana Corporation CONTACT:
Jeff Cole of Dana Corporation, +1-419-535-4704, or email, Web site:
http://www.dana.com/ Company News On-Call:
http://www.prnewswire.com/comp/226839.html
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