Integrated Front End Module System

Compression-molded SMC was used on the first North American implementation of integrated front-end module (FEM) systems for cost, weight, and functional performance. Switching from metals allowed for significant parts consolidation, eliminating 22 major subcomponents and 27 fasteners/vehicle plus related design drawings/CAE models, stamping tools, gauges, fixtures, plus purchasing and logistical tasks. The single-piece 'ready-to-install' structural carrier with self-locating fasteners improved assembly operations, provided an 'open architecture' for powertrain installation, eliminated 9 line locations and 15 work-cell locations, reduced weight 22% and costs 14%, while boosting quality (R/1000) 22% vs. previous designs. Additional benefits included improved serviceability and documented reductions in collision insurance costs while meeting all safety requirements.

OEM/Vehicle Ford Motor Co. 1996 Ford Taurus & Mercury Sable sedans System Supplier Toledo Mold & Die Material Processor Budd Plastics Division

Material Supplier Budd Plastics Division Resin SMC

For More Information See: http://www.plastics-car.com/frontendvehicle