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1 Yanfeng Automotive Interiors (Established in 2015 as a joint venture between Yanfeng Automotive Trim Systems Co., Ltd, and Johnson Controls, Inc.) Heat Stake Redesign and Process Optimization Description of Project Heat staking is a high-volume, low-cost method of assembling plastic parts by aligning pins on one part with holes in a mating part, applying a controlled amount of heat and pressure, and melting the pins to form a permanent fastener. The primary function of heat stake fasteners is to join two parts rigidly together, with a maximum amount of strength and no relative movement. Heat staking is used widely in automotive interiors, for its ability to join dissimilar plastics and to join plastics to other materials. The staking process is capable of forming many attachments simultaneously without additional fasteners, reducing handling and assembly time. FIGURE AUTOMOTIVE DOOR PANEL WITH MULTIPLE STAKED COMPONENTS AND DETAIL The quality of this process is vitally important to the customer because failure causes loose or misaligned components. Loose components produce objectionable squeaks and rattles. Misaligned components produce visually objectionable gaps, and are difficult to assemble. Because of these risks, finished part quality is 100% inspected visually, and periodically verified by tensile testing to failure. Page 1 of 5

2 The student team will redesign the geometry of the pin and hole, optimize the process conditions, to maintain connection strength, minimize cycle time and reduce variation in finished part quality. Phase 1: BASELINE GOAL Product Optimization Students will propose a short list of redesigned pin geometries each supported by analytical modeling predicting results. Students will work with YFAI tooling staff to convert their new pin designs into functional molds and produce test parts. Process Optimization After developing an understanding of the heat stake technique and proving the on-campus equipment, students will determine the optimal process conditions (operational temperature, pressure and compression time) which result in consistent product quality and minimized cycle time for the status quo geometry and then again for the optimized product geometry. Phase 2: Stretch Goal 1 Students will redesign a version 2 pin design based on results from validation of Phase I and prove additional benefits based on analytical modeling. Phase 3: Further Stretch Goals (any of these options would be valuable) Research resin properties and additives that could improve heat staking performance and work with resin suppliers to identify a material that would better deliver the required performance. Develop improved methods of clamping, heating and staking that require less space between fastener locations. Collaborate with advanced manufacturing engineering staff to develop a feedback control system to reduce variation in the staking process. Location Work will take place on campus with periodic visits to the manufacturing site to work with staff and develop an understanding of the scope of the challenge. Heat stake equipment will be located in the Wilson Center on north campus. (MDP will provide transportation). Page 2 of 5

3 Project Sponsor Mentor Dennis VanHouten is a product engineer at the Yanfeng Technical Campus in Holland, Michigan. Dennis graduated from the University of Michigan (BSME 93) and Grand Valley State University (MBA 99). Dennis has over 20 years of experience in automotive interiors, including roles in research and development, testing, product design, and Six Sigma. He currently mentors product development and launch teams in the use of Taguchi methods for Robust Engineering. Project Faculty Mentor Johannes Schwank, James and Judith Street Professor of Chemical Engineering; Director, Electron Microbeam Analysis Laboratory (EMAL) His research program is focused on fundamental and applied research problems in heterogeneous catalysis, sensors, and energy storage materials. A major theme is the development of correlations between surface structure of materials and their reactivity. Key Skills & Project Roles Project Roles Mechanical Design and Development (2-3 students) Materials Development (2-3 students) Structural Part Design, Analytical Structure Modeling with phase changes/heat transfer Material testing, heat transfer modeling, Likely Majors Mechanical Engineering, Materials Science, Chemical Engineering, or Mechanical Page 3 of 5

4 Statistics and Experimental Design (1-2 student) Plastics behavior, Injection molding Design of experiments and analysis of experimental results Engineering, Statistics, or any major with advanced experimental design coursework Desired Additional Skills/Knowledge/Experience: (any of these skills would be a desirable addition to the team) CAD skills, particularly Catia, injection molding experience, understanding of plastics chemistry, mechanical aptitude Company Overview Yanfeng Automotive Interiors is the world s leading supplier of instrument panels and cockpit systems, door panels, floor consoles and overhead consoles. Headquartered in Shanghai, the company has more than 90 manufacturing and technical centers in 17 countries and employs over 28,000 people globally. Established in 2015, Yanfeng Automotive Interiors is a joint venture between Yanfeng Automotive Trim Systems Co., Ltd, a wholly owned subsidiary of Huayu Automotive Systems Co., Ltd. (HASCO), the component group of SAIC Motor Corporation Limited (SAIC Motor), and Johnson Controls a global multi-industrial company. Capabilities at the Yanfeng Technical Campus in Holland, Michigan include the following: Advanced engineering Injection Molding Benchmarking Mold Tooling CAE, CAD, Mold Flow Innovation Consumer Research Materials Lab Cut, Sew & Wrap Product Development Industrial Design Studio Product Planning Human Factors Lab Process Prove-out Yanfeng global manufacturing capabilities include the following: Project management Prototype Shop Purchasing Quality Systems Safety Analysis Structural Analysis Page 4 of 5

5 1 and 2 Step Painting Adhesive Bonding Automated Edge Folding Automated Part Transferring Back Molding with Natural Fiber Compression Forming Foams and Fibers Fabric Cutting Foam-In-Place Thermoforming & Urethane Foam Pre-Forms Heat Staking Ultrasonic, Infra-red and Vibration Welding In-Mold Applique/Decoration Molding In-Mold Grain Vac Forming Injection Molding Leather and Artificial Material Wrapping Manual and Programmable Sewing Multi-Color Injection Molding Pad Printing Positive and Negative Vac Forming Powder Cast/Foam-In-Place Press-Fit and Threaded Fasteners Legal Requirements Citizenship and Right to Work Options: This project is open to all students regardless of citizenship status Intellectual Property Agreements / Non-Disclosure Agreements: Students will sign an NDA/IP for YFAI (MDP template available) Internship Information Summer Funding Application Available Yanfeng is proud of its summer internship program, which offers challenging assignments throughout the United States. Yanfeng offers competitive wages, housing, social support and networking opportunities for dozens of exceptional interns each year. For more information, please visit Page 5 of 5