Automotive Assembly

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Today, just about every square inch of a typical automobile is crammed full of electronic components. Microprocessors, sensors, connectors and other increasingly smaller and more robust devices are inside doors, under seats, behind dashboards, inside tires and under hoods.

Several manufacturers have earned multiple OSHA VPP Star awards at one location. Others, like Hendrickson U.S.A LLC, have achieved Star status at multiple locations.

In his recent State of the Union address, President Obama challenged Americans to be more innovative. That means developing new materials, new products and new production processes. To tackle that challenge, manufacturing engineers must harness the power of “smart assembly” tools and systems.

Many manufacturers want to be a Star, regardless of how long they’ve been in business or the products they make. Since July 1982, OSHA has helped thousands of manufacturers become a Star through its Voluntary Protection Programs.

Although many people use training and education interchangeably, the words don’t mean the same thing.

The Reshoring Initiative aims to educate manufacturers about the true costs of outsourcing.

Aluminum wire and cable can be more difficult to feed, cut, crimp, strip and splice than its copper counterparts. However, numerous processing methods are currently under investigation.

Modular conveyors provide the flexibility to create a variety of layouts when assembling prismatic multicell battery modules.

Recent price fluctuations have forced some manufacturers to consider alternatives to copper wire, such as copper-clad aluminum, solid-core aluminum and composite wire.

Electric vehicles promise to transform the automotive landscape. But, don’t expect to see too many differences in assembly plants as automakers start ramping up production.