Category: Blog EN

What is a Tier 1 automotive company?

empresa de tier 1

In the automotive industry, as in many others, a system of classification by levels or tiers exists. These tiers categorize suppliers in a supply chain based on their proximity to original equipment manufacturers (OEMs), the risks they pose, and the significance of the products or services they offer. In this article, we will delve deeper into the concept of being a Tier 1 automotive company. We’ll explore what it takes for a company to earn this classification and highlight the differences compared to Tier 2 and Tier 3. Understanding TIER 1 in the Automotive Industry In the automotive sector, Tier 1 companies are suppliers that manufacture components or systems sold to original equipment manufacturers (OEMs)—companies that design and assemble vehicles. Tier 1 suppliers often play a crucial role in the industry by providing OEM manufacturers with components or systems essential for producing safe, efficient, and appealing cars. Maintaining close relationships with vehicle manufacturers, they frequently collaborate to create high-quality products that seamlessly integrate into vehicles. Similar to vehicle manufacturers, Tier 1 suppliers constantly innovate, developing new products that meet customers’ evolving needs. Components and systems typically manufactured by Tier 1 companies include engines, transmissions, brakes, interior elements, suspension systems, steering components, electronics, and security systems, among others. Requirements for a Tier 1 Supplier in the Automotive Industry What does it take for a company to be considered a Tier 1 supplier? To earn this classification, a company must meet high standards of quality, safety, and efficiency, among other criteria. Some of the conditions required include: High Quality: Tier 1 companies must provide high-quality parts and systems that meet strict standards set by car manufacturers. This involves compliance with safety regulations and rigorous tests to ensure performance. Safety: Manufactured parts must not only be of high quality but also reliable and safe for both drivers and passengers. Compliance with the industry’s stringent safety standards is essential. Efficiency: Given the large demand and strict delivery deadlines from car manufacturers, Tier 1 suppliers must be operationally competent to meet production and supply chain requirements efficiently. Innovation: The dynamic nature of the automotive industry requires Tier 1 companies to continually innovate, developing new products and applying cutting-edge technologies. It’s worth noting that these are general requirements, and each company may have specific criteria based on its operations and the type of components or systems it supplies. Role of Tier 2 and Tier 3 in the Automotive Sector What functions do Tier 2 and Tier 3 companies serve in the automotive industry? These suppliers provide components or raw materials to Tier 1 suppliers. Tier 2: Tier 2 suppliers are usually smaller companies than Tier 1 but specialize in manufacturing specific components essential for the latter. They typically produce metal parts such as axles, frames, and bodies, plastic parts like bumpers, headlights, or interior panels, and electronic components such as screens, sensors, processors, and even plastic parts with integrated printed circuits. Tier 3: Tier 3 manufacturers produce materials or equipment for Tier 1 and 2 companies. They manufacture raw materials like plastic, rubber, steel, and aluminum, as well as tools and equipment used by companies. Additionally, they provide engineering, testing, and logistics services. In our case at Walter Pack, we specialize in developing innovative solutions for our customers. We focus on designing and producing decorative and functional plastic parts for sectors such as automotive and home appliances. We take pride in our commitment to sustainability and efficiency in our manufacturing processes.

Decarbonization in the automotive sector

descarbonización en la automoción

One of the greatest challenges our planet faces is climate change. Greenhouse gas emissions from human activities continue to worsen the problem as their consequences become more apparent. In order to address this issue, various decarbonization processes have taken place in different industries, especially in the automotive sector. Through measures such as adopting electric vehicles, using renewable energy, and implementing more efficient technology, the goal is to reduce our carbon footprint, creating a cleaner and more sustainable environment in the long term. In this article, we will not only make you aware of the importance of decarbonization in the automotive industry but also in other sectors. You will discover what this process entails, the long-term benefits it poses, and the necessary steps to achieve the objective. What is Decarbonization? In simple terms, decarbonization is a process that involves reducing or eliminating carbon dioxide (CO2) emissions, as well as other greenhouse gases, which result from human activity. The primary aim of this process is to mitigate climate change and all its associated consequences by opting for low-carbon or entirely neutral alternatives. Certain processes, such as the burning of fossil fuels like coal, oil, or natural gas, release significant amounts of CO2 into the atmosphere, contributing significantly to the greenhouse effect and, consequently, global warming. Therefore, decarbonization involves transitioning from such fuels to cleaner and renewable energy sources, including solar, wind, hydroelectric, geothermal, and even nuclear energy, which contribute minimally or not at all to CO2 emissions. While this process is not exclusive to the automotive industry, it extends to other sectors, as we will see later. Industrial Decarbonization Industries such as construction, livestock, agriculture, manufacturing, and transportation are largely responsible for greenhouse gas emissions and temperature increases due to their energy-intensive processes, use of fossil fuels, or harmful chemicals damaging the ozone layer. To address climate change, it is necessary to fulfill international commitments regarding emission reduction. Additionally, a combination of strategies and key technologies must be applied to achieve long-term industrial decarbonization: 1. Energy Efficiency Decarbonization and energy transition are essential to reduce CO2 emissions in the industry. This process involves optimizing production processes, minimizing energy losses, and adopting more efficient equipment. 2. Use of Renewable Energy Many industries are adopting renewable energy sources such as solar, wind, biomass, and hydroelectric power. Popular alternatives include installing solar panels or wind turbines to generate clean energy. 3. Electrification Replacing fossil fuels with electricity is also a trend. Many industrial processes that once relied on fossil fuels now use technologies like electrolysis and electric heating, allowing the use of renewable energy while reducing emissions. Electrification is also present on a smaller scale in sectors like construction, where electric machinery like lifts, forklifts, and excavators are being preferred. 4. Circular Economy and Recycling A growing alternative is the transition to a circular economy, where waste and by-products are reused instead of discarded. This can help reduce pollution and emissions in the long run by efficiently utilizing materials and resources, decreasing the need for extracting and producing new products. Transformation in the Automotive Sector Despite continuous advancements in the efficiency and reduced fuel consumption of internal combustion engine vehicles, the path to decarbonizing the automotive sector is one of the most challenging, requiring accelerated adoption of electric vehicles. Meeting emission reduction goals has become challenging due to various external factors. The automotive industry must contend with inconsistent international regulatory frameworks and limited access to the raw materials needed for electric car production, along with a lack of competitive green business models. Fortunately, change is occurring naturally, driven by emission regulations and consumer demand. Factors such as competitive pricing, high technological integration, excellent range, and zero emissions, both CO2 and noise, have captured consumer attention, creating a market that was hard to imagine a few years ago. The road to decarbonization is complex and filled with challenges, but not impossible. With the increasing demand for electric cars, the adoption of green production processes, and the mentioned measures, we may achieve the goal of decarbonization in the not-so-distant future, not only in the automotive industry but also in other sectors. There is no doubt that the planet’s decarbonization process will be arduous and time-consuming, but it is undoubtedly necessary for our future and that of future generations. At Walter Pack, we advocate for sustainable and planet-friendly solutions by opting for highly automated and efficient machinery and processes.

Expanded polypropylene(EPP):top material in the automotive industry

polipropileno expandido

Over the years, the automotive industry has developed a multitude of materials for the manufacture of parts, with expanded polypropylene being one of them. At Walter Pack, we want to tell you what polypropylene is, its properties, and its most common uses in the industry, taking advantage of our vast experience in the development of parts for the automotive sector… What is expanded polypropylene and properties? Expanded polypropylene is a type of expandable resin that is composed of 98% air, so it is extremely lightweight. It is also known for its great mechanical strength, which is why it is used in multiple applications in various industrial sectors. EPP, developed in the 1970s, was the result of various research into new forms of polypropylene. It began to be used in Japan in 1982 to manufacture automotive products, and it is currently one of the industries that use it the most, due to its lightness, flexibility, and high impact absorption. As for manufacturing, it is usually quite complex, as it depends on two important factors: technical knowledge and specialized equipment for it. The whole process requires several phases, under strictly controlled environmental conditions. The procedure begins with the mixing of the polypropylene resin with other ingredients. The extruded granules are expanded until they become foamed polypropylene beads. Subsequently, the EPP beads are injected into multi-cavity molds, where the heat of the steam combined with the pressure causes these beads to fuse, taking the shape of the mold. EPP is available in different grades depending on the application and technical requirements. High-density grades are used in applications where a high energy management is required, such as the case of automobile bumpers and interior safety elements for passengers. There are also low-density grades, which are used for packaging applications. Finally, medium-density grades are used to manufacture furniture and various consumer items. Properties of expanded polypropylene As mentioned, EPP has multiple properties. The most important are: ·       It has great mechanical and chemical resistance. ·       It is resistant to compression. ·       It is resistant to moisture. ·       It has good insulating properties, both thermal and acoustic. ·       It is lightweight. ·       It is durable. ·       It has a high impact absorption. Applications and benefits of polypropylene in the automotive industry Due to all these properties, it is a material that can be used in various applications, with the construction of automobile parts being one of the most important. That is why we will explain the use of this material within this industry. Interior elements The first thing we must mention is its great energy absorption capacity and its lightness, two essential qualities for developing parts such as shock absorbers and air grilles. These components must be lightweight to optimize the weight of the car. In the same way, thanks to its high impact absorption, EPP is used to manufacture other components for the car cabin, such as headrests, door seals, and other shock absorbers. This guarantees the safety of passengers in the event of an accident. Floor components EPP is also used to manufacture floor components. They are used to level the floor of the vehicle, thanks to the fact that it is a highly flexible material with which complex shapes can be designed. Luggage compartment accessories Similarly, it is used to make tool accessory kits, spare wheels for the luggage compartment, battery covers, among others. The reason for this is that it is a resistant material, so much so that it has enough strength to hold tools securely in the luggage compartment. Armrests Also, EPP is used to make armrests, thanks to its strength and the fact that it does not suffer permanent deformation. This means that it returns to its previous shape when the pressure is stopped. At the same time, it offers stability and comfort. Headrests and seat inserts Similarly, polypropylene foam EPP is used to manufacture headrests. Headrests, being a passive safety component, have to be manufactured with excellent quality materials that provide the driver with the correct protection in the event of an accident. Its great resistance to damage and great comfort make it perfect for this, not to mention that it is also used to manufacture car seat inserts, due to being a profitable and lightweight material. At Walter Pack, we are always looking for materials that provide our customers with the best performance for their projects. That is why we use EPP to manufacture decorative and functional parts for sectors such as automotive or white goods, among others. We take advantage of its properties to create lightweight parts that can withstand wear and tear.

DFMA – Design for Manufacturing and Assembly

diseño para la fabricación y montaje

The application of DFMA is essential today, especially as companies are always looking for ways to reduce costs, improve efficiency and, of course, improve product quality. In this sense, this technique is incredibly beneficial, as it is used to facilitate the manufacturing and assembly process of products. No matter what stage of development it is in, it can be applied at each stage. From the development of the idea to its manufacture. In short, with DFMA, obstacles that hinder the creation of the product can be identified and eliminated. What is DFMA? DFMA (Design for Manufacturing and Assembly) is a set of methodologies created with the purpose of “challenging” the design. Thanks to these tools, the complete design process can be studied systematically to ensure its optimization and prevent unnecessary future costs. This industrial design method originated in 1983 and was created by Drs. Boothroyd and Dewhurst. With the advent of DFMA, many companies in sectors such as IT, furniture, agricultural machinery and automotive were able to save large sums of money in manufacturing, assembly and maintenance of their products. The reason for this is that it is much easier to make changes at the beginning of the design process, regardless of whether it is a new product or an existing one. Now, DFMA is governed by the following rules: ·       The design must be as simple as possible, which eliminates unnecessary features. ·       Use standard materials and processes to make the development and assembly of the device simpler. ·       Minimize the number of parts so that the manufacturing cost is lower. ·       Make the product easy to assemble and thus reduce the need to use specialized tools for this. In fact, modular assembly is quite attractive for DFMA, since in this case it is possible to transform a product without losing its overall function. In other words, the less custom-made parts have to be developed, the more time will be available to focus on other specific product problems. Benefits of Design for Manufacturing and Assembly Now, for the application of DFMA, it is important to analyze some principles, which provide the following benefits. The first point to analyze is the product’s process and life cycle. Here, the appropriate manufacturing process for the product must be chosen and its life cycle must be foreseen. In this sense, DFMA helps to understand all the manufacturing phases to correctly estimate its final cost, that is, the one that is closest to reality (the management cost chain is analyzed). Also, DFMA favors team organization, as it improves communication between design, manufacturing, purchasing, etc. departments. This increases creativity and knowledge about the product, which results in a decrease in costs. On the other hand, with DFMA, the product architecture is investigated. In other words, its functions and possibilities are studied, which is very important because it must be known if the product can withstand the environment. Finally, the design and development is studied. This means that, to achieve advanced product development, it is necessary to have knowledge of innovative manufacturing technologies, materials, product parameters such as tolerances, and future users or customers. By applying DFMA, all this data is obtained, which is essential for choosing the right option. It is clear that the application of DFMA is very beneficial when designing and manufacturing a product. For example, it can be made so that the correct orientation of a part is obvious, so as to waste less time in the assembly process. This is fixed by making a small notch in the part to indicate the correct way to place it. The important thing in the end is to consider the design process as a whole and, in this way, develop a product that meets all the stages we have mentioned. There is no ideal design plan, so the most advisable thing is to opt for an integrated approach. Of course, the reduction in costs and development time will always be the goal of any company, so applying DFMA is a good solution to achieve this, without forgetting the needs of the user. At Walter Pack, we follow a strict methodology in the development of our products, to ensure that we provide our customers with high-quality parts in the shortest possible time. If you are interested in our services, contact us to find out how we can help you.

Interview with Laura del Hoyo

Interview with Laura del Hoyo R&D Leader at Walter Pack “Our greatest challenge is integrating sustainability into any innovative process we undertake.” For several years now, sustainability has become an unwavering goal for Walter Pack and a ubiquitous challenge for its R&D department. The new head, Laura del Hoyo, is aware of the complexity of balancing this goal with the research of new materials and processes in the demanding automotive world. However, she insists on the need to explore new technologies to achieve it: “We must continue working to achieve aesthetics similar to those obtained with virgin materials using recycled materials.” Q. A. Artificial Intelligence, sustainability, Industry 5.0… We are in a moment loaded with challenges for your department. What would you say are the main challenges for Walter Pack’s R&D? The main challenge, almost a necessity, is to work towards the sustainability of our products and our business. In recent years, sustainability has become integrated into the automotive sector, one of our main areas of business, to the extent that everything must have a sustainable component. For example, if we consider integrating Artificial Intelligence into our processes or products, we must do so in conjunction with that factor. Our greatest challenge is to integrate sustainability into any innovative process we undertake. Q. A. You recently participated in BAT in an event on innovation in the industrial value chain with EI Manufacturing. Has the use of sustainable materials in the industrial sector shifted from being an option to becoming an obligation? Indeed, sustainability is no longer optional but a necessary element in the industrial value chain. While all players in the sector have considered it for some time, regulatory regulations implemented over the last three or four years have encouraged us to focus on it in terms of innovation. Q. A. What do major automotive and home appliance manufacturers demand from their suppliers regarding sustainability? Customers want suppliers and ODMs to incorporate recycled components into their products and the components we manufacture through a dual approach: either they ask us to use a specific percentage of recycled materials in their production, or to use parts with accredited sustainable value, for example, demonstrating that they come from the circular economy. “Our clients ask us to incorporate recycled materials into the parts or demonstrate that they come from the circular economy.” Q. A. In the current global market, what is the value proposition that allows Walter Pack to maintain its competitiveness? On the one hand, we need to leverage Walter Pack’s traditionally proven strengths as a manufacturer of decorated and functional films, and on the other, strengthen our commitment to sustainability-related innovation. This means combining our technological strength with a sustainable contribution. We are already experts in this technology, in the production of high-value decorative plastics that integrate functionality. Now, we will add sustainability to our products and offer this option to our customers to provide high added value to the components of their vehicles. Q. A. Q. A. Walter Pack presented a project at the EI Manufacturing event with Birziplastik and Gaiker on circular economy applied to materials. What does it consist of, and what role does each party play? The project is part of Walter Pack’s commitment to deepen the circularity of processes and materials. Its goal is to recover our main waste, the surplus that is not part of the decorative component and was previously discarded, to give it a second life. We want to integrate it into the type of final product we produce. Birziplastik handles the first link in the chain, performing the treatment to convert that waste into a size suitable for Gaiker to process. The technological center then transforms the material to give it the properties needed for reuse as injection material, adding the necessary additives for the mechanical properties required by automotive products. From that point on, we can process the product to produce fully functional plastic parts. What phase is the project currently in? At the moment, we are conducting the necessary laboratory tests to replicate the living conditions of this piece inside a vehicle. In parallel, we have started working with other types of cuttings to do the same with other materials. “We presented a project at BAT with the aim of reusing and integrating our waste into the final product” Q. A. Q. A. What timelines have been set? This project is of an R&D nature and concludes as such in 2024. After that, we would have to move to a development phase to, if applicable, achieve approval and offer it. When it concludes, what added value could it bring to Walter Pack? On the one hand, it would allow us to offer our customers a product from the circular economy in which our waste would act as substrate material, where applicable. On the other hand, it would give us an economic competitive advantage because we wouldn’t need to acquire virgin material as raw material, and we could offer more economical solutions composed of our own waste. Additionally, using this discarded material would allow us to save on the current waste management in environmental terms. “This project would allow us to offer more economical solutions composed of our own waste and save on waste management.”” Q. A. Is this the only project your R&D department is currently involved in in this field? Sustainability is one of Walter Pack’s strategic lines, and within it, we are working on several projects simultaneously. One aims to incorporate other waste found in other sectors, such as bottle caps, into our manufacturing processes to become part of the decoration of our pieces. We are also involved in the European Treasure project, which focuses on the disassembly and subsequent recycling or reuse of the elements that make up plastronics components in the automotive sector. Q. A. Q. A. What do events like the one organized by EI Manufacturing mean for Walter Pack and the industry as a whole? Such events represent a great opportunity for companies