To: BWAC  who wrote (314 ) 9/25/2002 8:51:00 AM From: JakeStraw     Respond to    of 397  Delphi Announces GM As First U.S. Customer For Electric Power Steering  Brownfield Location Gears Up For E*STEER Production Using Lean Manufacturing And Award-Winning Processes  Wednesday September 25, 8:05 am ET biz.yahoo.com  TROY, Mich., Sept. 25 /PRNewswire/ -- Delphi Corporation (NYSE: DPH) has secured electric power steering business with General Motors for future applications. A 55,000 square foot brownfield redevelopment manufacturing location in Buena Vista Township, Michigan prepares for the start of E*STEER(TM) Electric Power Steering production. The new facility will utilize state-of-the-art lean manufacturing principles and two Delphi award-winning manufacturing processes, Math Based Metal Removal and high precision gear set machining. (Logo: newscom.com  ) In January 2001, the Michigan Economic Development Corporation (MEDC) granted Delphi a Brownfield Redevelopment Single Business Tax Credit, which is designed to encourage new investment in obsolete facilities. The MEDC also provided additional support to the project via a three year Economic Development Job Training Grant. "Bringing the new E*STEER business to our Buena Vista site was the result of hard work and collaboration between our local and state government. We worked collectively with our UAW partners on creative solutions that enabled us to meet competitive challenges," stated Robert J. Remenar, president of Delphi Saginaw Steering Systems. "Both UAW Local 699 and Delphi management have developed an innovative manufacturing plan that enabled the placement of this business in Saginaw." The redevelopment of the facility in Buena Vista Township began in June 2001. The facility, which will be able to produce more than 400,000 E*STEER systems annually, features 12 lean work cells instead of traditional assembly lines. This single plant will produce and assemble the full electric power steering system including the steering column, assist mechanism, intermediate shaft, and rack and pinion gear, which will then be delivered to the customer as a single module. In addition to lean cells, other lean manufacturing approaches used in the redevelopment included flexible installation of machinery, one-piece flow within cells, and small lot material handling strategies. The new E*STEER plant is using Delphi's Math Based Metal Removal (MBMR) process, which won a 2001 Premier Automotive Suppliers' and OEMs' Contribution to Excellence (PACE) Award as the industry's first implementation of modeling of machining in a personal computer-based intelligent software system. Using this process, Delphi engineers can now use virtual machining to optimize machining parameters prior to ever setting foot on the plant floor. This optimization tool helps remove subjectivity and provides improvements to cycle time and quality. The E*STEER plant has specifically used MBMR to improve the assist mechanism housing machining process. Through computer-based analysis, engineers changed the path of the tool, reduced non-cut time and changed the sequence of the cycle to eliminate delays and combine moves. Overall MBMR allowed an 11.6% improvement in cycle time. Another award-winning Delphi process being applied in the plant is the manufacturing of a high precision plastic worm gear set, which is another first in the automotive industry. The hybrid worm gear set is designed to improve responsiveness in the electric steering mechanism. This manufacturing process evolved from the challenge of cutting precision plastic gears versus conventional metal gears and garnered a team of five Delphi engineers, including one from Delphi Steering's Spain facility, a 2001 Boss Kettering Award. "In a continuous effort to remain competitive and meet future market needs, manufacturing organizations must continue to evolve," stated Remenar. "At Delphi that evolution involves a strong focus on future technology and advanced processes that are leading the industry and enabling us to deliver high performance, high quality products to our customers." Delphi's E*STEER Electric Power Steering technology won a 1999 PACE Award. That same year Delphi began production for European customer, Fiat, followed by Volkswagen in 2001, and has since produced more than 1.5 million units.