January_2021_AMP_Digital

A D V A N C E D M A T E R I A L S & P R O C E S S E S | J A N U A R Y 2 0 2 1 2 7 (AS1), two blanking lines (BL1 and BL2), and a roll-forming line (RF). The exis- ting two large transfer presses (P1 and P2) and the two high-speed progres- sive lines (AP1 and AP2) would be re- furbished and upgraded. Finally, the traditional scrap conveyor system would be replaced with a new cyclon- ic system, capable of sorting four scrap streams. This innovative design was made possible by isolating the door in- ners—the only large parts made of al- loy 5182—in P2, which became the only press line capable of sorting four ways (Figs. 5 and 6). The frame plant was scheduled to cease frame production in Septem- ber 2011 with the demise of the Panther platform. The plant would be com- pletely redone and transformed into a state-of-the-art aluminum parts man- ufacturing plant, to be renamed Dear- born Diversified Manufacturing Plant. The refurbished plant would include three complete tube forming lines and machining lines, two heat treat ovens, and a chemical surface treatment line. A later expansion to support the Ford Super Duty and Expedition/Navigator models would add two tube forming lines and an additional heat treat oven. The consolidation of so many parts into Dearborn Stamping Plant re- quired finding room to house multiple sub-assembly lines that were formerly spread out among several other plants. The solution was for the stamping plant to annex part of the Dearborn engine plant that housed the former fuel tank production lines. Ford’s Buffalo Stamping Plant was set to produce thick gauge 6111 struc- tural parts. It already had one press line connected to a single stream cyclon- ic system. The new material specifica- tions brought improved composition compatibility, allowing the existing low copper stream to be readily mixed with the much higher volume of 6111 scrap, thus avoiding an expensive up- grade. With Ford now scheduled to han- dle more than 85% of the stamping by weight, the remaining parts were divid- ed between two local suppliers, Thai Summit in Howell, Michigan, and Vel- tri, just across the river in Windsor, Ontario. The part sourcing pattern was carefully managed tominimize both scrap sorting complexity and the investment required at both suppliers. By mid-year, the design team had selected the winning theme and the studio was now finalizing all details of the clay models. Engi- neering of the underbody was well underway to support the upcoming fleet of development prototypes. Novelis publicly announced a $200 million automotive expansion to its Oswego, New York, plant on July 25, 2011, without mentioning Ford. Orders for Dearborn Stamping Plant’s new press lines were out by Fig. 5 — Four-way scrap system at the Dearborn Stamping Plant, as configured at the F-150 launch in September 2014. Fig. 6 — East side cyclones and sorting tubes at Dearborn Stamping Plant, September 2014. Courtesy of L. Chappuis.