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Dana Corporation Demonstrates Manufacturing Flexibility with Toyota Tundra Frame
TOLEDO, Ohio, Nov. 13 /PRNewswire-FirstCall/ -- Dana Corporation's Owensboro,
Ky., facility has demonstrated its flexibility by implementing a lean assembly
process to manufacture an extended frame for the all-new Toyota Tundra Double
Cab pickup. Toyota selected Dana to supply a frame that is more than a foot
longer than standard frames for the longest and widest version of the Toyota
Tundra.
(Logo: http://www.newscom.com/cgi-bin/prnh/19990903/DANA )
The pickup truck, available this fall, is more than 230 inches long from
front-to-back. The extra length of the frame was achieved by designing the
regular tooling to accept the additional length of the new side rails. The
assembly process incorporated automatic changeovers to continue the
lot-size-of-one capability. The design also incorporates additional
reinforcements for strength and performance. Dana people worked on one part of
the frame at a time beginning with the rear stub, where the frame required the
most significant changes.
"In a little over a year's time and without disrupting current production, we
were able to reconfigure our manufacturing process to accommodate a frame that
is more than 5 percent longer than the current version," said Bill Carroll,
president of Dana's Automotive Systems Group. "This is truly a great success
story for our customer and Dana alike, and showcases our manufacturing
flexibility."
When faced with the challenge of producing the extended truck frame efficiently
and within a tight deadline, Dana integrated improved manufacturing processes
within current production space. Working closely with Toyota, Dana engineers
implemented 14 new assembly cells piece by piece, resulting in a seamless
transition at the start of production.
In addition, the Tundra program team incorporated new automated processes that
accomplish more tasks in less space. One example is a new automated welding
cell that simultaneously welds three frames in the space previously required to
weld just one. It takes just over one minute for the team members at Dana to
produce a complete frame. Continuing the Owensboro plant's drive for
flexibility, production rates can be reduced or increased to continue
just-in-time sequential delivery under varying market demands.
"This is a great example of how Dana works with customers to manufacture
specialized, high-quality products efficiently," Mr. Carroll added. "Employees
from every level of the organization worked together to make the launch
successful, meeting Toyota's high expectations."
Dana's Owensboro plant manufactures frames for all Tundra pickups and Sequoia
sport-utility vehicles and employs approximately 330 people. Dana has been
producing frames for Toyota for more than 10 years.
Dana Corporation is a global leader in the design, engineering, and manufacture
of value-added products and systems for automotive, commercial, and off-highway
vehicle manufacturers and their related aftermarkets. The company employs
approximately 60,000 people worldwide. Founded in 1904 and based in Toledo,
Ohio, Dana operates hundreds of technology, manufacturing, and customer service
facilities in 30 countries. The company reported sales of $9.5 billion in 2002.
Dana's Internet address is http://www.dana.com/ .
http://www.newscom.com/cgi-bin/prnh/19990903/DANA
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DATASOURCE: Dana Corporation
CONTACT: Jeff Cole of Dana Corporation, +1-419-535-4704, or
email,
Web site: http://www.dana.com/
Company News On-Call: http://www.prnewswire.com/comp/226839.html