Case Study
GKN Structures develops improved
chassis for flagship JCB vehicle
When leading machinery manufacturer JCB wanted to improve one of its flagship vehicles, the company enlisted the help of GKN
Structures to further enhance chassis performance.
Specialists in the design, development and manufacture of
structural assemblies and chassis systems for the automotive
market, GKN Structures was the ideal strategic partner for the
project. As part of GKN Land Systems, the Structures team was
able to draw upon the wealth of experience across the business
and leverage group-wide technologies and expertise.
The project was focussed on developing the chassis of the JCB
Fastrac, a tractor range targeted at the agricultural, military and
aviation ground support markets. JCB wanted to improve the
lifespan and durability of the chassis.
GKN Structures quickly identified that its e-coating process
would be an immediate advancement for the Fastrac chassis.
This method uses an electric current to deposit paint, offering
superior base coat performance in comparison to standard
powder or wet coating processes. GKN has a dedicated area
for e-coating with the capacity to handle the particularly large
Fastrac chassis, which can weigh more than 1,000kg. The
facility utilises an advanced 17 tank process, which includes
pre-treatment, the electrocoat, post rinse and the bake oven.
Highlights
•
Bespoke solution to meet a specific need by a leading
off-highway vehicle manufacturer
•
GKN Structures had the capability to transform the
complete chassis manufacturing process and the
scale of facility to handle the large Fastrac chassis
•
Enhanced chassis has significant impact on vehicle
performance and durability
•
The benefits to JCB include reduced handling costs
and improved quality and control
•
JCB has now awarded the manufacturing contract to
GKN for all Fastrac chassis
Not only is the coating highly resistant to corrosion,
but the electro-deposition also allows coating of
intricate and hard to reach areas of a part. In
addition, the water based paint system
has less impact on the environment and
the transfer efficiencies of more than 95%
result in reduced paint waste.
The JCB Fastrac is one of the company’s flagship vehicles.
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The new coating system is complemented by adoption of highly
efficient manufacturing techniques. Simon Cubitt, Business
Development Manager for GKN Structures, explains: “As well as
introducing e-coating, we showed our capability to transform
the entire chassis production process. From the laser cutting of
the steel, through to the assembly and then shot blasting, GKN
utilises lean manufacturing wherever possible, which lowers
costs for its customers.
“Further to this, we are able to demonstrate our commitment
to continual improvement and reduction of waste through the
application of the GKN continuous improvement program.”
Following the success of a pilot project, GKN Structures has
been awarded the contract to plate process, fabricate, weld and
paint all JCB Fastrac chassis and supply them to the company’s
assembly lines.
Through the newly formed partnership JCB will benefit from
single source, onsite processing at GKN Structures’ site in
Telford. In addition JCB will see reduced handling costs,
as well as improved quality and control.
JCB wanted to improve the lifespan and performance of the
Fastrac chassis.
Testimonial
“It has always been JCB’s philosophy to design, develop
and manufacture ‘world class’ products that deliver
beyond the expectations of the modern day consumer.
JCB chose to build a strategic partnership with GKN
Structures because they offer superior technical
expertise in product design, manufacturing, quality
management and coating systems. There is no doubt
that this partnership will continue to strengthen and
generate future business growth, for both companies.”
Peter Ellis - Quality Manager, JCB Landpower Ltd,
manufacturer of the Fastrac product.
The improved chassis will deliver benefits for the agricultural market,
as well as military and aviation ground support.
GKN Structures Headquarters, PO Box 85
Hadley Castle Works, Telford TF1 6TE
United Kingdom
Tel: +44 (0) 1952 428053
Web: www.gknlandsystems.com
GKN Structures is a world leader in the design, development and manufacture of pressed steel, structural assemblies and chassis
systems for the automotive market. The company employs around 660 people.
It is part of the GKN Land Systems Division of GKN PLC. Land Systems is a global organization with over 5,000 employees worldwide
and annual sales of more than $1.1 billion (£699 million). It is one of four divisions within GKN plc, the others being Aerospace,
Driveline and Powder Metallurgy. GKN plc is a global engineering business serving the automotive, aerospace and land systems
markets. It has operations in more than 30 countries, around 40,000 employees in subsidiaries and joint ventures and had sales of
£5.4 billion in the year ended 31 December 2010. GKN plc is listed on the London Stock Exchange (LSE: GKN).
www.gkn.com
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