Dana Corporation Demonstrates Manufacturing Flexibility with Toyota Tundra Frame

Nov 13, 2003

    TOLEDO, Ohio, Nov. 13 /PRNewswire-FirstCall/ -- Dana Corporation's
(NYSE: DCN) Owensboro, Ky., facility has demonstrated its flexibility by
implementing a lean assembly process to manufacture an extended frame for the
all-new Toyota Tundra Double Cab pickup.  Toyota selected Dana to supply a
frame that is more than a foot longer than standard frames for the longest and
widest version of the Toyota Tundra.
    (Logo: http://www.newscom.com/cgi-bin/prnh/19990903/DANA )
    The pickup truck, available this fall, is more than 230 inches long from
front-to-back.  The extra length of the frame was achieved by designing the
regular tooling to accept the additional length of the new side rails.  The
assembly process incorporated automatic changeovers to continue the
lot-size-of-one capability.  The design also incorporates additional
reinforcements for strength and performance.  Dana people worked on one part
of the frame at a time beginning with the rear stub, where the frame required
the most significant changes.
    "In a little over a year's time and without disrupting current production,
we were able to reconfigure our manufacturing process to accommodate a frame
that is more than 5 percent longer than the current version," said Bill
Carroll, president of Dana's Automotive Systems Group.  "This is truly a great
success story for our customer and Dana alike, and showcases our manufacturing
    When faced with the challenge of producing the extended truck frame
efficiently and within a tight deadline, Dana integrated improved
manufacturing processes within current production space.  Working closely with
Toyota, Dana engineers implemented 14 new assembly cells piece by piece,
resulting in a seamless transition at the start of production.
    In addition, the Tundra program team incorporated new automated processes
that accomplish more tasks in less space.  One example is a new automated
welding cell that simultaneously welds three frames in the space previously
required to weld just one.  It takes just over one minute for the team members
at Dana to produce a complete frame.  Continuing the Owensboro plant's drive
for flexibility, production rates can be reduced or increased to continue
just-in-time sequential delivery under varying market demands.
    "This is a great example of how Dana works with customers to manufacture
specialized, high-quality products efficiently," Mr. Carroll added.
"Employees from every level of the organization worked together to make the
launch successful, meeting Toyota's high expectations."
    Dana's Owensboro plant manufactures frames for all Tundra pickups and
Sequoia sport-utility vehicles and employs approximately 330 people.  Dana has
been producing frames for Toyota for more than 10 years.
    Dana Corporation is a global leader in the design, engineering, and
manufacture of value-added products and systems for automotive, commercial,
and off-highway vehicle manufacturers and their related aftermarkets.  The
company employs approximately 60,000 people worldwide.  Founded in 1904 and
based in Toledo, Ohio, Dana operates hundreds of technology, manufacturing,
and customer service facilities in 30 countries.  The company reported sales
of $9.5 billion in 2002.  Dana's Internet address is http://www.dana.com .

SOURCE Dana Corporation

Web Site: http://www.dana.com

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