New Paint Process In Valladolid Plant

3 wet process & 2 Colors Car

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT
The Industrial Scheme

 Valladolid (Spain): A western Europe plant to be converted from 60 to

45 JPH and to be modernized to produce efficiently a new car

 For paint process, some opportunities:

 Produce 2 tones car by using free existing capacity

 Validate with few investment a 3wet process in industrial facilities

 Carry over of existing sealing robots from 2 lines to 1 line to solve

obsolescence

 The Main Scope:

 A new 2 colors Car

 A new 3 wet process

 A new durability performance with High Scratch resistance Clear Coat

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 2
The New 2 Tones Car

Captur:
B Segment Cross Over

5 doors

SOS: March 2013

Production Location: Valladolid

Plant Capacity: 45 JPH

21 outside colors combinations

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 3
The 3 wet Process

 What’s exactly a short process?

 2010: ~10 000 black vehicles produced in Valladolid with 2 wet process,
the best economical short process solution

 Decision to give up this solution due to limited color range possibilities

 => Decision for 3wet / 1 FO technology

B0 BCi BC1 / BC 2 CCi CC

Bell Gun Bell Bell Flash Off Interior Bell

warm air

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 4
 The 3 wet Process: a short schedule for a short process

Captur SOP
Captur Trials

May 2012 Jan. 2013 MA

Product
2011 2012 2013
Validation
June 2011 Déc. 2011 Aug. 2012

T4 2010: Project
Kick off
Decision Facilities
Go / noGo modification

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 5
The 3 Wet Process
 Material validation with 3 suppliers involved: PPG - BASF – B&K

 Homologation and lab tests on 4 critical colors

 Trials in Valladolid plant without investment

 Color and appearance validation on Modus painted in Valladolid Plant

 30 cars manufactured with each supplier

 Process Modification during 2 Shutdowns by Durr & Finitech

 Process and Product optimisation on Modus Serial life to ensure

robustness before Captur SOP

 Next step running: only 1 bake for sealing

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 6
The 2 Tones Process

 Request for extra capacity to produce 2 tones car

=> Opportunity of free capacity in paintshop vs T&C at 45 JPH

 Process Adaptation for masking and unmasking

 Total Delivery Cost optimization by 2 tones limit definition

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 7
Valladolid & Captur: A success story

 Successful modernization of a Western Europe Plant to make it

profitable and allow to receive a new vehicle

 First successful short process implementation for Renault =>

Process decided for all Greenfield and firstly for China project

 First 2-colors car with high production capacity

 Commercial success confirmed for Captur !

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 8
 Thank you

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 9
Annexes

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 10
Short Process or Short Processes

Sealing: 1 Waterborne 2wet Inside App. First

Or or Or or Between
2 baking solventborne 3 wet BC0 – BC1

2 x 2 x 2 x 1,5 x

Warm FO BC2 in 1 1K
Or
Ambiant FO 2 steps
Or Or
2K Clear Coat
=
96
Product & Process
2 x 2 x 2 solutions for A short
process

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 11
Valladolid Topcoat Lay out
Use Bcint for B0 application

Line A

EMU BCint BC1/2 FO CCint CC

Line B

EMU BCint BC1/2 FO CCint CC

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 12
 EMU and BC Pipes moved from 10 m – new 2K PCS

 2x10 m booth with Stop&Go conveyor system

 B0 Station

Robot : PE133
Bell: Ecobell 2 External Charge

BCi

B0

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 13
1st color
Oven Inspection
BC+ CC

2nd color Masking

Oven
BC+ CC

Unmasking Inspection

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 14
Opportunity of free capacity in paintshop vs T&C at 45 JPH

Line A: 30 JPH

EMU BCint BC1/2 FO CCint CC

Line B: 15 JPHLine
1st color 15 JPH 2nd Color
B: 30+JPH

EMU BCint BC1/2 FO CCint CC

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 15
2 tones Process

Quality
Check 1st Color

Masking

Touch up Unmasking
2nd Color

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 16
80
60
Op Time
40 75
(min)
45
20
0
Sol 1 Sol 2

CONFIDENTIEL
10 Juin 2013 PROPRIÉTÉ RENAULT 17