Manufacturing

Fast Fact

AAM has invested approximately four billion dollars in capital expenditures efficiently and appropriately.

AAM incorporates leading-edge manufacturing technology into the production of driveline and drivetrain systems and components, and metal-formed products. Advanced manufacturing processes are key to our industry leadership for supplying innovative, quality products, faster and more economically to global automotive markets. At AAM, cutting-edge technology advances the wide range and sophistication of our global manufacturing processes, and enables our lean-concept approach.

At AAM, engineering and manufacturing are fully integrated, allowing better-designed products to get to the assembly line and the consumer faster and more efficiently. As a result, the driveline systems and components we supply - including those for all-wheel-drive and crossover vehicles - provide the world-class quality and delivery that vehicle manufacturers and tier suppliers need for a major program advantage.

 

AAM advanced manufacturing technology and capabilities include:
  • Factory Information System (FIS) - Allows view of the factory operation any time, any place; analyzes operating efficiency, helping assure first-time quality.
  • Traceability - Incorporates a "birth certificate" for each product, allowing complete traceability, including metallurgy.
  • Quality Information System (QIS) -  Uses an RF Tag  to gather all manufacturing information.
  • Manufacturing Engineering Desktop (MEDT) - Captures and integrates product information, process sheets PFMEA, APQP.
  • Manufacturing Line Simulation - Lines are built in 3-D virtual reality, allowing dynamic-mode line simulated operation prior to line build.
+ Lean Concepts
+ Quality Policy

Metal-Formed Products
Our metal-formed products manufacturing combines industry-leading metal-forming expertise with advanced process and systems technology to deliver products that continually set new standards of quality, performance and durability. Products include axle and driveline components; transmission components; transfer case/power transfer unit components; chassis and steering components; wheel hubs and spindles.

 

In addition to producing world-class-quality metal-formed products, AAM supports a number of post-process capabilities including induction hardening, carburizing, annealing, spline rolling and machining including grinding and polishing - in some cases measured down to microns.

AAM manufacturing success is built on technology and processes that include:

  • Machining Technology - Flexible/modular systems utilizing selective automation, FMEA driven process design, Materials, cast iron/steel (aluminum/magnesium), methods (turning, milling, boring, hobbling,  ID & OD grinding), metrology (machining - 0.010 to 0.025 mm, grinding/hard turning - 0.003 to 0.009 mm), management (standard world wide processing), high speed machining, hard turning, shrink fit tooling, dry cutting and MQL (Minimum Quantity Lube), linear drive machining centers, surface topography analysis.
  • Welding Technology - Gas metal arc welding (GMAW), resistance welding (RW), laser welding, magnetic impelled arc butt welding (MIAB), friction welding, welding dissimilar materials, weld vision inspection system, flexible fixture-less tooling, automatic robot error recovery and friction.
  • Heat Treating Technology - carburizing / carbonitriding, furnace temper (stress relief), plasma / ion nitride, controlled cooling furnaces, computerized process control, part tracking, induction hardening and tempering
  • Assembly Technology - flexible/convertible systems, component-level birth certificates, PFMEA driven error proofing, selective fit of robotic automation, ergonomic work stations, one-piece-flow work flow, PC/PLC control architecture, electric servo presses/drives, vision systems, dynamic measuring systems, closed-loop process feedback, DC torque tooling, tool-less quick change tooling
  • Product Validation - If we make it, we can test it on our broad range of rapid prototyping and specialized testing equipment. At AAM, we test and validate components, modules and complete systems - 24 hours a day, 7 days a week, 362 days a year.

Process Development Center
AAM's Process Development Center is home to state-of-the-art manufacturing process development. The core activities consist of the following:

  • Process Optimization & Standardization
  • Cycle-time optimization
  • Advanced tool development
  • Process standardization
  • Machine turnkey integration
  • Fixture design & integration
  • Tooling design & implementation
  • Process capability verification
  • CMM programming, fixturing & integration
  • Prototype machining optimization

These projects are focused on supporting AAM's profitable global expansion, by developing, optimizing and standardizing flexible manufacturing processes which give AAM a true competitive advantage.

 

 

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