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To remain competitive in the fiercely contested North American automotive industry, the New United Motor Manufacturing Inc. (NUMMI, Fremont, CA) assembly plant, a joint venture between Toyota Motor Corp. (Aichi Prefecture, Japan) and General Motors Corp. (Detroit), has rededicated its efforts in lean manufacturing during the past few years by applying key tenets of the Toyota Production System (TPS). 

Basic trends in modern manufacturing are driving growth in 3D optical metrology. “One is the highly complex and high-tech material that manufacturers are using today. For example, in the aerospace turbine blade market, they simply cannot touch the part like they used to—the surface finish of the material is too readily affected by any kind of contact metrology."

GE Appliances (GEA) has been designing and manufacturing consumer appliances for over 125 years. The iconic brand, headquartered in Louisville, KY, employs nearly 6000 people, a number that rose to 12,000 employed globally after its acquisition by Haier, making the company part of the largest appliance manufacturer in the world.

Manufacturers are accelerating use of Internet of Things (IoT) technology, according to a survey of 66 companies.

Challenged by an increasingly niche-oriented automotive market, The Chrysler Group (Auburn Hills, MI) must increase the number of models it offers while decreasing its capital investment. The company plans to offer 50% more models in 2009 compared to 2004, according to John Felice, VP of manufacturing, technology and global enterprise for Chrysler.

When a contract manufacturer sees an opportunity in the competitive aerospace market, it sets priorities aimed at providing the right combination of processes required to meet the industry’s exacting demands. Precision machining and finishing, parts inspection, and, of course, certifications from OEMs and industry alliances are at the top of the list. Increasingly, aerospace suppliers like Volvo Aero Connecticut (Newington, CT) are benefiting from five-axis machining, advanced CNC controls, motors and drives, robotic deburring, and on-machine inspection for a competitive advantage.

Although drivers may not know it, cable connections for the airbags and seatbelt buckle systems in their vehicle simply would not work without components manufactured by ODW-Elektrik. A development partner and supplier for high-quality cabling, solenoids and mechatronic systems used in vehicles around the world, ODW-Elektrik supplies most of its products to Bosch, Autoliv, Brose, VW, and ZF.

At UGN, one of our core operating principles is sustainability. That means minimizing waste to improve efficiency, add value, and refine the manufacturing process for our automotive products when and where we can.

Manufacturing Engineering asked thought leaders at five companies for their views on challenges and trends facing the metalworking industry.

Lean manufacturing principles and automation systems can coexist, although many lean purists contend that lean goals conflict with using automation. Smart applications of automation, however, can result in deployment of systems that are both automated and lean, with flexible manufacturing systems that can be easily reconfigured as factory operations change.