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No / This paper presents a framework for life prediction modelling and illustrates it with a case study of a plastic automotive component subjected to competing failure mechanisms: wear, leading to a soft failure-degradation of functional performance, and fatigue, leading to loss of function through fracture of a main sub-component. The paper focuses on developing a life prediction model for the fatigue failure mechanism. Structural and kinematic analysis of the component was conducted to identify a suitable substitute load characteristic for the failure mechanism. The aim is to develop an approximate model using limited testing data and when a baseline stress-life model is not available. The issues highlighted by the case study are generic to development of life models for non-critical automotive components, thus providing potentially wide scope for practical application of the approach.

Materiais compostos de matriz metálica (CMM) vêm sendo estudados para diversas aplicações. Entretanto, pouco estudo é apresentado na sua confecção a partir de materiais reciclados. Este trabalho teve como objetivo a caracterização de um material composto de matriz metálica (CMM), utilizando material reciclado como matéria prima. Foram usados aparas de chapas de liga de alumínio 2024 descartados para a matriz e carbeto de silício (SiC) como reforço, sendo a produção realizada através do processo de fabricação com base na técnica de conformação por spray para possível aplicação em componentes automotivos. Foi realizado o tratamento térmico do material e a caracterização, determinando as propriedades de dureza, resistência mecânica, resistência ao desgaste, MEV e EDS. Foram ensaiadas amostras do material composto fundido e extrudado, bem como de ferro fundido de uma peça automotiva e da liga de alumínio 2024. Observou-se que o CMM ainda precisa de melhorias no processo de produção para obter propriedades de dureza e resistência que permitam que ele possa ser usado como um substituto para o ferro fundido, porém o mesmo apresentou melhores propriedades quando comparado com o material da matriz. / Metal matrix composites (MMC) have been studied for several applications. However, little study is presented in its manufacture from recycled materials. This study aimed to characterize a metal matrix composite (MMC), using recycled material as raw material. Were used aluminum alloy 2024 plates clippings discarded for the matrix and silicon carbide (SiC) as reinforcement, being the production accomplished through the manufacturing process based on the technique of spray forming for possible application in automotive components. The thermal treatment and the characterization of the materia was accomplished, determining the properties of hardness, mechanical strength, wear resistance, SEM and EDS. Were tested samples of the cast and extruded composite material, as well as cast iron of an automotive part and aluminum alloy 2024. It was observed that the MMC still needs improvements in the production process to obtain properties of hardness and strength that allows it to be used as a substitute forcast iron, but it presented better properties when compared with the matrix material.

Materiais compostos de matriz metálica (CMM) vêm sendo estudados para diversas aplicações. Entretanto, pouco estudo é apresentado na sua confecção a partir de materiais reciclados. Este trabalho teve como objetivo a caracterização de um material composto de matriz metálica (CMM), utilizando material reciclado como matéria prima. Foram usados aparas de chapas de liga de alumínio 2024 descartados para a matriz e carbeto de silício (SiC) como reforço, sendo a produção realizada através do processo de fabricação com base na técnica de conformação por spray para possível aplicação em componentes automotivos. Foi realizado o tratamento térmico do material e a caracterização, determinando as propriedades de dureza, resistência mecânica, resistência ao desgaste, MEV e EDS. Foram ensaiadas amostras do material composto fundido e extrudado, bem como de ferro fundido de uma peça automotiva e da liga de alumínio 2024. Observou-se que o CMM ainda precisa de melhorias no processo de produção para obter propriedades de dureza e resistência que permitam que ele possa ser usado como um substituto para o ferro fundido, porém o mesmo apresentou melhores propriedades quando comparado com o material da matriz. / Metal matrix composites (MMC) have been studied for several applications. However, little study is presented in its manufacture from recycled materials. This study aimed to characterize a metal matrix composite (MMC), using recycled material as raw material. Were used aluminum alloy 2024 plates clippings discarded for the matrix and silicon carbide (SiC) as reinforcement, being the production accomplished through the manufacturing process based on the technique of spray forming for possible application in automotive components. The thermal treatment and the characterization of the materia was accomplished, determining the properties of hardness, mechanical strength, wear resistance, SEM and EDS. Were tested samples of the cast and extruded composite material, as well as cast iron of an automotive part and aluminum alloy 2024. It was observed that the MMC still needs improvements in the production process to obtain properties of hardness and strength that allows it to be used as a substitute forcast iron, but it presented better properties when compared with the matrix material.

Increasing energy efficiency is critical towards mitigating greenhouse gas emissions from fossil-fuel combustion, reducing oil dependence, and achieving a sustainable global energy system (Greene, 2011:608). Most South African legislation and research scholars support the above statement; however, with a lack of tangible evidence, the statement is yet to be proved physically true in the South African manufacturing industry. A case study was conducted within three automotive component manufacturers located in Nelson Mandela Bay Metropolitan Municipality, with the objective of identifying energy efficiency projects; investigate the perception of company employees on energy efficiency and assessing whether there are benefits for the companies when implementing such projects. For the research methodology, the mixed mode method was used. Quantitative data was collected using energy assessments and a questionnaire was used for the collection of qualitative data. The quantitative and qualitative findings clearly demonstrate that company managers and operational staff need to have a clear understanding of the concept of 'energy efficiency'. Efficiency projects implemented include automated compressors, changing hot-water geyser settings, installation of power factor correction, and tariff structure changes. The quantitative recommendations were centered on switching off equipment when not required. As an alternative, the use of sensors, timers and other automated control devices should be investigated and implemented where feasible. Qualitatively recommendations advise that companies with employees who do not understand energy efficiency, training and awareness programmes need to be applied. Employees would then be able to put their energy saving knowledge into action. This study demonstrated that there is a need for further research to be undertaken, to improve efficiency for energy within the automotive manufacturing industry. / Environmental Management, Department of Environmental Science / M. Sc. (Environmental Management, Department of Environmental Science)

The South African automotive industry has experienced significant changes in the last 20 years. Globalisation, the implementation of lean production and the development of modularisation have had a profound influence on the relationships between original equipment manufacturers (OEMs) and their suppliers, the automotive component manufacturers (ACMs), and their suppliers. South Africa has a number of OEMs and a vibrant automotive component manufacturing industry (ACM), which supplies the South African aftermarket and a spread of export markets. These ACMs are the focus of this study. The main objective of this research study was to identify the supply chain management problems ACMs in South Africa encounter, to what extent they face these problems and how these can be overcome. The problems were identified through a literature review and interviews with two OEMs in South Africa. Using this data a questionnaire was compiled and sent to all NAACAM members for completion. This study is by nature descriptive and exploratory and contains quantitative and qualitative elements. Seven hypotheses were formulated to guide the research. The findings of this research indicate that the geographic location, age and size of the business, have no bearing on the supply chain problems ACMs face, whist the relationship between ACMs and their suppliers and ACMs and their customers is a significant problem. The findings also indicate that the following are some of the main supply chain problems facing ACMs: pressure by OEMs to reduce prices; the price of materials; cancellation of orders; excessive inventory; the unreliability of rail transport and rail capacity problems; the high cost of South African ports; the cost of replacing outdated technology; and BBBEE – achieving and verifying BEE scorecards. The findings further indicate a lack of skills and labour problems, both of which are time consuming to resolve. This study was completed over a four-year period. At the commencement of this study the automotive industry was booming, but in mid-2008, a global economic crisis started. This crisis impacted adversely on the automotive industry globally and in South Africa. Despite these challenges, leaders in the South African automotive component industry remain positive about the future. This study was completed over a four-year period. At the commencement of this study the automotive industry was booming, but in mid-2008, a global economic crisis started. This crisis impacted adversely on the automotive industry globally and in South Africa. Despite these challenges, leaders in the South African automotive component industry remain positive about the future. / Business Management / D. Comm. (Business Management)

The South African automotive industry has experienced significant changes in the last 20 years. Globalisation, the implementation of lean production and the development of modularisation have had a profound influence on the relationships between original equipment manufacturers (OEMs) and their suppliers, the automotive component manufacturers (ACMs), and their suppliers. South Africa has a number of OEMs and a vibrant automotive component manufacturing industry (ACM), which supplies the South African aftermarket and a spread of export markets. These ACMs are the focus of this study. The main objective of this research study was to identify the supply chain management problems ACMs in South Africa encounter, to what extent they face these problems and how these can be overcome. The problems were identified through a literature review and interviews with two OEMs in South Africa. Using this data a questionnaire was compiled and sent to all NAACAM members for completion. This study is by nature descriptive and exploratory and contains quantitative and qualitative elements. Seven hypotheses were formulated to guide the research. The findings of this research indicate that the geographic location, age and size of the business, have no bearing on the supply chain problems ACMs face, whist the relationship between ACMs and their suppliers and ACMs and their customers is a significant problem. The findings also indicate that the following are some of the main supply chain problems facing ACMs: pressure by OEMs to reduce prices; the price of materials; cancellation of orders; excessive inventory; the unreliability of rail transport and rail capacity problems; the high cost of South African ports; the cost of replacing outdated technology; and BBBEE – achieving and verifying BEE scorecards. The findings further indicate a lack of skills and labour problems, both of which are time consuming to resolve. This study was completed over a four-year period. At the commencement of this study the automotive industry was booming, but in mid-2008, a global economic crisis started. This crisis impacted adversely on the automotive industry globally and in South Africa. Despite these challenges, leaders in the South African automotive component industry remain positive about the future. This study was completed over a four-year period. At the commencement of this study the automotive industry was booming, but in mid-2008, a global economic crisis started. This crisis impacted adversely on the automotive industry globally and in South Africa. Despite these challenges, leaders in the South African automotive component industry remain positive about the future. / Business Management / D. Comm. (Business Management)