Technology Roadmap for Energy Reduction in Automotive

Body in White and
Components
Paint
Powertrain and
Chassis Components
Final Assembly
Plant Infrastructure
Energy Efficient
Manufacturing &
Production for Existing
Materials
Energy Efficient
Manufacturing &
Production for New
Materials
Energy Efficient Design
of Products and
Processes
Organization of the Report
Exhibit 1.1. Technology Roadmap Workshop Topics
Major Operations
Production of body structure: tool manufacture, welding, castings, joining, robotics
assembly, non-ferrous materials/parts/ fluids, body construction
Application of interior/exterior paint and finish: paint booths, ovens, compressed air,
abatement, coatings, materials, waste treatment
Integration of engine, transmission, and chassis components: castings, net shape
casting and forging, forming, heat treating, machining/cutting/ tooling, powdered
metals, robotics assembly
Assembly of parts and components to produce finished vehicle: assembly
processes, robotics, final inspection of vehicles
Utilities and building envelope: generation, distribution, and maintenance of power
and heat and utility systems; HVAC and other building utilities; O&M of plant-wide
systems such as compressed air, motors and other equipment
Crosscutting Topics
• Materials that improve efficiency of the existing manufacturing process (heat
transfer, improved tooling/tool coatings, machining, etc.)
• Energy efficient processes for production and use of next generation materials
in vehicle design (use the same or less energy when incorporating new
materials)
• Efficient transfer/transport of parts and materials
• Design for recycle, predictive manufacturing for waste elimination/reduction
• Design for parts consolidation, reduction of content, elimination of process
steps – all to reduce energy use
This report is organized around the major operations shown in Exhibit 1.1. For each area,
information is provided on the scope (technologies and processes included); how the operation
might look or change in the future (i.e., a vision for the future); opportunities for energy savings;
and R&D priorities.
In each chapter, a summary table provides a list of the
priorities for reducing energy intensity in the major
operational area. These ideas have been compiled into a set
of priority R&D topics for each area, with greater detail
provided on performance targets, relative benefits, the
barriers to be overcome, specific avenues that might be
pursued through R&D, and major milestones.
Chrysler Warren Truck Assembly Plant,
Dodge Ram Box line, Body in White
TECHNOLOGY ROADMAP FOR AUTOMOTIVE MANUFACTURING ENERGY REDUCTION 2