Body Exterior
Number 45
Plastic Running Board
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2007 General Motors Trailblazer / Envoy
Mytox, Magna Decoma
Mytox, Magna Decoma
Mytox, Magna Decoma
Myplas 40 Myplas 40 PP Long
Glass Fiber
0
Person Making Nomination:
Summary:
Deane Nelson
0
Deane Nelson
(905) 850-4323
0
(905) 850-4323
0
0
Tom Pickett / Paul Viscomi
(586) 492-2454
General Motors
thomas.pickett@gm.com
The innovation in design (structural ribs) and material (a long glass fiber PP) allowed for a running board
to withstand higher loads and lower deflections at operating temperatures required by GM. Existing
competitor plastic running boards in a one piece design would not satisfy GM requirements. Part
consolidation: Components (3 brackets / fasteners, steel structure, TPO top cover) of running board
designed into one piece running board. Plastic material replaced steel for structural application.
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
The innovation in design (structural ribs) and material (a long glass fiber PP) allowed for a running board to
withstand higher loads and lower deflections at operating temperatures required by GM. Existing competitor
plastic running boards in a one piece design would not satisfy GM requirements.
Part consolidation: Components (3 brackets / fasteners, steel structure, TPO top cover) of running board
designed into one piece running board. Plastic material replaced steel for structural application.
A modified 2 stage injection molded process.
No.
Metal formed understructure. Injection molded top cover. Metal formed brackets.
No special tooling innovations required to produce this part.
MYPLAS 40 is a PP long glass fiber weatherable material that was specially developed to meet GM Material
requirements of GMP.PP-PIM.002 for this running board.
Vehicle mass savings for GMT360 running boards were 28 pounds per vehicle. A 50% mass reduction
compared to previous metal design.
Direct cost savings in excess of $19.00 per vehicle.
Reduced assembly complexity and total cycle time of the running board (5 parts into 1). Mold in brackets
eliminated fasteners.
Yes. Lower weight and aerodynamics improved fuel economy. Eliminated squeak & rattle noise. Improved
corrosion resistance.
Yes, this product technology is being applied to many vehicle lines.
Non applicable.
Material is recyclable. Offers better fuel economy.
GM running boards have a higher structural load requirement than other OEMs. Existing designs of one
piece plastic running boards would not meet the GM structural part performance requirements. The design
innovations of the type and location of the ribs
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Body Interior
Number 1
Door Trim Module
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2006 Chrysler Caliber, Compass and Patriot
Grupo Antolin
IAC
Dow
0 702-20 Polypropylene
HiTech
Person Making Nomination:
Summary:
Ian Thompson
248-373-1781
Ian Thompson
Bill Lamontagne
Not known
248-373-1781
248-371-8961
0
Mike Olbrys
248-852-6600
Grupo Antolin
ian.thompson@grupoantolin-usa.com
Integration of components, this unique module concept combines all door hardware components and the
trim panel into one module, directly sequenced into the plant fully tested vastly reducing amount of online
stations at vehicle assembly plant Includes two shot bolster winner from last year
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
Integration of components, this unique module concept combines all door hardware components and the trim
panel into one module, directly sequenced into the plant fully tested vastly reducing amount of online stations
at vehicle assembly plant
Includes two shot bolster winner from last year
Injection molding and two shot for the bolster
This is the first of its kind in the US market place. Grupo Antolin introduced the concept first in Europe on
vehicles like the Renault Megane, Seat Leon, Seat Altea and more
The current market options are 1. Conventional build: all hardware is assembled separately into door at
vehicle assembler. 2. A hardware module is assembled to the vehicle with all hardware but still requires a
finished trim to be assembled on top
Deep draw towers for regulator mounting, very careful design in lifters for tool. Control of edge condition
important to maintain seal and fit condition of door
None other than impact properties which any trim requires for side impact
conventional build are mainly around 10% saving of total system weight. In carrier modules ranges from
around 600g for a small module like Wrangler up to 2500g for a module like Dodge Ram
Estimates range from $10 to $17 per vehicle total savings to OEM. Majority comes through assembly
operation reductions and parts being directly sequenced to line
Sequencing costs are vastly reduced, OEM storage space reduced. If new plant then major reduction in linme
and operators required (dependant on union agreement with OEM)
No Glass fiber reinforced plastic carrier required
Yes, application already in place with other OEMs in Europe. Discussions in place for further applications of
this concept continue
Part met all requirements for Chrysler to gain 5 star side impact rating
Less fasteners as trim integrates many of the attachment features
This has been a very successful module launch for Chrysler
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Body Interior
Number 13
NVH Trunk Load Floor
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2008 Ford Motor Company Ford Focus
Polywheels Manufacturing
Polywheels Manufacturing
Quadrant Plastics Composites
0 0 NA
Service Mold Inc.
Person Making Nomination:
Summary:
Greg Burkhardt
734-853-5616
Greg Burkhardt
Greg Burkhardt
Richard Broo
734-853-5616
734-853-5616
248-360-6084
Dan Westlake
519-945-3344 x228
Polywheels Manufacturing
gburkhardt@polywheels.com
A extemely light weight trunk load floor with improved NVH performance Manufacturing process that
eliminated secondary operation to bond carpet to substrate
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
A extemely light weight trunk load floor with improved NVH performance
Manufacturing process that eliminated secondary operation to bond carpet to substrate
Thermoforming
In North America this is the first use of this material/ process for trunk load floors
Previous substrates were primarily made out of compressed wood fiber prooducts
Thermoforming tool is able to form part to maximize load capacity performance and complete the carpet
trimming in a one-step operation
Needed to complete molding & load testing analysis to determine optimum material density & lofting/ molding
thickness to maximize load capacity & NVH performance
57% or 4lb weight save (3 lbs vs 7 lbs.)
Ford Motor Company identified product as providing cost & freight savings
Eliminated planned freight from India to Ford Wayne Assembly Plant, Livonia MI
Reduced weight for improved MPG & improved sound absorbtion
Yes, application transferable to other vehicle programs
NA
Elimimated previous wood fiber substrate to reduced cutting down of trees
After all other weight save options had been incorporated, the Focus program still needed to reduce weight to
meet Vehicle Class requirements. Polywheels developed, designed, validated and launched application in
less than 12 months.
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Body Interior
Number 40
Structural Console Side Panel
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2008 General Motors Cadillac CTS
Draexlmaier Automotive
Plastic Tec
Bayer
Bayblend T-88 2N Glass Filled
PC/ABS
Delta Mold
Person Making Nomination:
Mark Vincent
0
0
248-622-0997
0
0
Jim Quinn
(704) 588-6600
Sabrina Groshek
(810) 533-9022
General Motors Coproration
sabrina.groshek@gm.com
Summary:
Structural features of side panel enables console assembly to meet styling and structural requirements
with reduced mass and a more efficient assembly process. Stiffncess in thes structural Panels allowed
"Flow Through" Console Design that:
1. Reduced airflow restrictions to rear seat ducts, 2. Allowed Cadillac Styling to achieve desired flow through theme, 3.
Achieved proper level of stability and rigidity
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
Structural features of side panel enables console assembly to meet styling and structural requirements with
reduced mass and a more efficient assembly process.
Stiffncess in thes structural Panels allowed "Flow Through" Console Design that:
1. Reduced airflow restrictions to rear seat ducts, 2. Allowed Cadillac Styling to achieve desired flow through
theme, 3. Achieved proper level of stability and rigidity
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
Injection Molding using Sequential Valve Gates
No
Replaced conventional Injection molded side panel from Polypropylene
Sequential Valve Gating
The use of Glass Filled PC/ABS allowed the part design to achieve strength and rigidity requirements while
enabling the elimination of several structural components.
480 Grams
Console cost was reduced by 3.3%
Assembly time savings of 14.5%
Enabled increased buckle clearance due to thinness of console side panels; Enabled increased bin storage
size; and Increased Airflow
This application can be translated to other products
0
0
0
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Chassis/Hardware
Number 34
Front End Module
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2007 Ford Motor Company Edge
Android
Meridian Automotive Systems
Ticona
Celstran PP-GF40 Glass filled PP
Omega
Person Making Nomination:
Erin Dahn
Steve Lakatos
Craig Dlugos
810-577-0680
313-253-4049
248-377-6853
Dino Mardegan
519-818-7574
Steve Pelczarski
313-253-3556
Meridian Automotive Systems
Spelczarski@meridianautosystems.com
Summary:
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
Injection molded
No
Replaced plastic/metal hybrid and steel front end structures.
20-30% weight savings over a welded metal structure.
30% saving over a welded metal structure
Yes
Yes
Recyclable
0
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Performance and Customization
Number 10
Rear Under Seat Storage System
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
Vikeda
Depo (Shanghai, China)
na
na na Polypropylene, 20%talc
na
Person Making Nomination:
Summary:
Paolo L. Catenacci
313 493 7795
2008 Chrysler Dodge Dakota
John Clarke
na
na
248 505 8057
na
na
na
na
Chrysler LLC
plc9@chrysler.com
First time any vehicle has had a foldable, removable, storage system creating convenience for the
customer Folds and hides away under rear seats when not in use. Snaps into vehicle and snaps together
tightly to eliminate BSR potential while driving of vehicle.
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
First time any vehicle has had a foldable, removable, storage system creating convenience for the customer
Folds and hides away under rear seats when not in use. Snaps into vehicle and snaps together tightly to
eliminate BSR potential while driving of vehicle.
Injection Molding
No
n/a
Typical tooling design used for interior plastic injection molded components with some lifter action in rim
areas of crates.
n/a
n/a
n/a
If other proposal was implemented, would have cost us $32 per vehicle more in piece price and would not
have been as innovative and convenient for the customer
Customer convenience to hold and contain groceries and other items inside truck while driving so as not to
travel and create mess. Can remove crates and bring into store and into house with you. Eliminates need for
bags, and cardboard ex. Costco
Can be built into any trunk area/cargo area of any vehicle with simple flat area and holes into floorpan
sheetmetal so as to mount the tray which the crates snap into..
n/a
Could eliminate the need for grocery bags and thus reduce waste.
Very rapid tooling program where production tooling was built in China and functional parts to build into pilot
vehicles in a total of 8 weeks. First parts were exceptional due to excellent design work from John Clarke at
Vikeda.
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Performance and Customization
Number 27
Bed Extender
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2006 Ford Motor Company P356 - F250
ABC Interior Systems
ABC Interior Systems
Salflex Polymers (ABC Group)
Sallfex S 815 PP GF
Supreme Tooling (ABC Group)
Person Making Nomination:
Summary:
Karl-Willi Meyer
416-742-4037 x4261
John Sudak
John Sudak
Brian Yawney
416-675-2220 x265
416-675-2220 x265
416-741-0273
Ted Szczucki
416-742-9600 x4121
ABC Group
karlwm@abc-tech.com
STRUCTURAL IN-COLOUR-BLOWMOULDED A-CLASS SURFACE (TEXTURED) BED EXTENDER
WITH MULTIPLE UNIQUE MODES OF EMPLOYMENT FIRST BLOWMOLDED BED EXTENDER,
THREE DIFFERENT MODES OF EMPLOYMENT - CARGO, STORAGE, STOWAWAY
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
STRUCTURAL IN-COLOUR-BLOWMOULDED A-CLASS SURFACE (TEXTURED) BED EXTENDER WITH
MULTIPLE UNIQUE MODES OF EMPLOYMENT
FIRST BLOWMOLDED BED EXTENDER, THREE DIFFERENT MODES OF EMPLOYMENT - CARGO,
STORAGE, STOWAWAY
BLOW MOLDING
YES
REPLACES ROLLFORMED STEEL OR ALUMINUM PROFILES AND PROVIDES ADDITIONAL FEATURES
PROPRIETARY PROCESS TO PRODUCE A-CLASS TEXTURE
MATERIAL DEVELOPED FOR BED EXTENDER TO SATISFY IMPACT, LOW TEMPERATURE, SCRATCH
AND MAR, WEATHER RESISTANCE AND COLOUR REQUIREMENTS
VS ALTERNATE DESIGN: TBD
VS ALTERNATE DESIGN: TBD
LESS PARTS - REDUCED QUALITY COST TBD, REDUCED ASSEMBLY COST TBD
UNIQUE THREE MODES OF DEPLOYMENT , INCREASES USEABLE BED SPACE ON PICK UP TRUCKS
FOR CUSTOMER, HIGH STRENGTH SOLUTION, INNOVATIVE STYLING,
YES, THIS APPLICATION CAN BE TRANSLATED TO OTHER VEHICLES AND OEMs
PROVIDES A SAFE AND EASY TO USE SOLUTION
COMPLETELY RECYCLABLE
GREAT GRAIN QUALITY ON AN A-SURFACE FOR SUCH A VERY LARGE BLOWMOULDED PART
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Powertrain
Number 20
Integrated Transmission Baffle/Seal Lip 2008 General Motors Chevy Malibu; GM Daewoo Tosca;
Buick LaCrosse China
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
Chunil Engineering
Chunil Engineering
DuPont Automotive
Hytrel Hytrel 7246 TPC/ET thermoplastic elastomer
Chunil Engineering
Person Making Nomination:
Summary:
Carole Davies
248.583.8112
Gwang Jun
Gwang Jun
Dino Tres
82-32-521-1101
82-32-521-1101
248.583.8172
Gwang Jun
82-32-521-1101
DuPont Automotive
carole.a.davies@usa.dupont.com
First integrated transmission baffle/lip seal system with single material - GM patent pending - eliminates
oil aeration for improved clutch durability to 200,000 miles; 50% increase in oil life; 45% improvement in
pump performance; smoother shift. Use of thermoplastic elastomer enables unique, GM patented design
for a single attachment ((current metal systems have appx. 10 attachment points that require rivets or
screws.))
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
First integrated transmission baffle/lip seal system with single material - GM patent pending - eliminates oil
aeration for improved clutch durability to 200,000 miles; 50% increase in oil life; 45% improvement in pump
performance; smoother shift.
Use of thermoplastic elastomer enables unique, GM patented design for a single attachment ((current metal
systems have appx. 10 attachment points that require rivets or screws.))
Injection Molding - one piece with integrated seals using hot runners
Yes
Previous Metal stamping or plastic carrier with rubber bead.
More a benefit in tooling - Natural elasticity of material allows part stripping without tear thereby eliminating
secondary operations. Hot runner valve gate direct injection
Unique heat stabilizer package; added resistance to automatic transmission fluid.
7X decrease in weight - 2 integrated baffle/seal lips per vehicle
20% direct, but initial design abandoned in favor of this option
Protection against failure (even at a 1% rate) saves 36 million. Additional $1 per part due to elimination of
secondary molding operations; significantly reduced scrap rate; improved cycle times
Improved shift for better ride and drive; improved environment (transmission fluid sealed for life of
tranmission) and improved horespower due to better pump efficiency
Yes and is - another OEM is considering adoption for new high-volume transmission program; generation 2 in
development with GM
N/A
Improved recyclability and reduced scrap; no automatic transmission fluid replacement; Energy saving owing
to weight reduction
2-year development cycle working in a global environment in an industry where averages run 5-7 years
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Powertrain
Number 26
Electric Water Valve Assembly
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2005 Nissan Titan, Armada, and Quest
Cooper-Standard Automotive
NA
DuPont Engineering Polymers
Zytel HTN 0 PPA
NA
Person Making Nomination:
Jay Patel
248.583.5748
John Croft
0
Jay Patel
248.454.3523
0
248.459.6573
0
0
DuPont Engineering Polymers
Jay.H.Patel@usa.dupont.com
Summary:
First single package, multi-function underhood water valve assembly to use overmolded joints assembly
module to delivery better heat/AC performance with lower cost and weight.
The valve incorporates an integrated plastic bracket and features Cooper-Standard's innovative over molded hose
connection technology. Light weight construction, dual functions, and accurate control. The valve drives
with a polarity controlled voltage at a low amperage provided by the Engine Control Unit.
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
First single package, multi-function underhood water valve assembly to use overmolded joints assembly
module to delivery better heat/AC performance with lower cost and weight.
The valve incorporates an integrated plastic bracket and features Cooper-Standard's innovative over molded
hose connection technology. Light weight construction, dual functions, and accurate control. The valve
drives with a polarity controlled voltage
Injection molding, overmolding, heat staking, thermo riveting, and ultrasonic welding.
No
Previously, the valve was manufactured out of metal that increased its weight. Constant tension clamps were
required at all hose connections contributing to a higher overall cost.
Not Applicable
Not Applicable
40% savings
15% savings
95% less current draw allows removal of vehicle control relay.
Yes, the consumer is able to obtain a vehicle that peforms better overall due to improved AC and heater
performance. Additional efficiences are achieved through weight reduction impacting fuel economy.
Yes, This product is designed to perform to global customer specifications.
Not Applicable
This valve contributes to greater fuel economy and increases vehicle recyclability percentage.
58% less pressure drop; 42% less internal leakage; 33% higher flow; 17% less external leakage; More
resistant to dust and water intrusion (IP67).
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Number 41
Process/Assembly/Enabling Technologies
Cut and Sew Seamless PAB
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
Draexl Maier
Draexl Maier
Benecke/Ticona
BENOVA/Selstran PP GF 30-02
PUR/LGF PP
HS Die
Person Making Nomination:
Summary:
2008 General Motors 2008 Cadillac CTS
Mark Vincent
Mark Vincent
Kelly Ordonio
248-622-0997
Mark Vincent
614-873-7255
Jim Fry
0
Sabrina Groshek
General Motors
(810)533-9022/(248)765-7948 sabrina.groshek@gm.com
Usage of Cut & Sew PUR laminated to an injection molded LG GF PP retainer coupled with the use of
innovative scoring technology was a key enabler for seamless PAB deployment in the 2008 Cadillac
CTS. Cut and Sew technology as applied in this application allows for increased styling flexibility and
enhanced appearance of the Instrument Panel. Enables tighter/crisper radii to be designed into the IP.
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
Usage of Cut & Sew PUR laminated to an injection molded LG GF PP retainer coupled with the use of
innovative scoring technology was a key enabler for seamless PAB deployment in the 2008 Cadillac CTS.
Cut and Sew technology as applied in this application allows for increased styling flexibility and enhanced
appearance of the Instrument Panel. Enables tighter/crisper radii to be designed into the IP.
Extrusion/Injection Molding
No
Typical Instrument panels use slush moulding process, RIM process, and foam and skin with discrete PAB.
Specialized scoring equipment developed for use with cut and sew PUR
0
Weight savings realized by the use of propietary spacing fabric developed for cut & sew PUR vs. PVC skin
with 8mm foam (up to 50%).
Cut and Sew PUR is a cost effective solution of volumes under 100,000 units. Savings is mainly in the area
of investment.
0
Improved perceptual quality due to enhanced craftsmanship of instrument panel, Improved NVH due to
dampening properties of PUR, Enables customization of Interiors (i.e. stitching, two tone colors)
Yes
0
0
0
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Environmental/Safety
Number 24
Head Rest Core for FMVSS-202a
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
Windsor Machine Group
Tegrant Corporation
JSP
Arpro 0 PP
Tegrant Corporation
Person Making Nomination:
Summary:
2008 Ford Focus
Kevin Pageau
2488354999
Greg Peltier
Kevin Pageau
Jeff Elgin
0
2488354999
0
0
0
Tegrant Corporation
kevin.pageau@tegrant.com
First EPP headrest insert used to meet FMVSS-202a static requirements. Unique snap fit design is
formed without slides or lifters, providing
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
First EPP headrest insert used to meet FMVSS-202a static requirements.
Unique snap fit design is formed without slides or lifters, providing
Steam chest molding
No
This is a new application for EPP
Tool was designed to accommodate integrated snap fits, to snap on the head rest rod.
None
Weight neutral versus non-compliant headrests, up to .5 lbs weight savings versus alternate designs in
injection molding or blow molding.
0
Significant piece price savings and tooling investment savings versus injection molding or other processes.
No
Will be used in numerous other Ford vehicles in the future.
First headrest using EPP for compliance with FMVSS-202a
None
0
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date
Environmental/Safety
Number 30
OEM Carbon Canister
System Supplier:
Material Processor
Material Supplier
Resin:
Tooling Supplier:
2007 Chrysler LX - (Charger, 300, Magnum)
Stant Manufacturing, Inc.
Stant Manufacturing, Inc.
BASF
Ultraform H4320 Blk120 Q 600
POM
Stant Manufacturing, Inc.
Person Making Nomination:
Summary:
Tim King
Tim King
Scott Nakon
765-827-8229
765-827-8229
734-934-5416
Tim King
765-827-8229
Scott Nakon
734-934-5416
BASF Corporation
scott.nakon@basf.com
Extruded Body that has a capacity adjustment which allows the Customer to tune the Carbon Load Rate
if needed without re-tooling the part. None that are able to be released
What is the single most unique or innovative
feature of this application?
Enter other innovative features of this
application not described above.
What process is used to produce this part?
Is this the first time this process was used to
produce this type of component?
Describe the materials, processes, or methods
previous used for this application.
Describe any special tooling innovations
required to produce this part.
Describe any special material developments
required.
Estimate the weight savings achieved versus
previous or alternative manufacturing methods.
Estimate the direct cost saving associated with
the application.
Estimate the indirect and/or cost avoidance
savings associated with the application.
Does this application result in any direct
consumer benefit, such as reduced interior
noise, higher engine horsepower, etc.
Can this application be translated to other
OEM's and/or vehicle lines?
Describe any SIGNIFICANT direct safety
benefits.
Describe any SIGNIFICANT direct or indirect
environmental benefits.
Please enter additional information you believe
the nomination committee should consider.
Extruded Body that has a capacity adjustment which allows the Customer to tune the Carbon Load Rate if
needed without re-tooling the part.
None that are able to be released
Extrusion (Body) and Injection Molding (End Caps, Load Plates)
Yes
Replaced Injection Molded Components
None
None
1.5 lbs/vehicle
Not Available
Tooling Costs
Reduced Evapoartive Emissions -lowere permeation rate material
Yes
None
PZEV Compliant Part - Reduced Evapoartive Emissions by using a lower permeation rate material
0
The above information (with the noted corrections) is to the best of my knowledge accurate. I understand that this information will be
used for publications, press releases, and other communication items. SPE may continue to edit and refine the above information.
_________________________
Signed
___________________
Print Name
___________________
Company
________________
Date