EU emission regulations has forced the automotive industry to adopt lightweighting strategies through material selection and design. There has been an industry focus on body in white lightweighting through the use of innovative materials, however, with manufacturing costs proving difficult to swallow, OEM's are exploring other options to reduce weight and meet CO2 emission requirements. With this in mind, the Automotive Lightweight Interiors Congress has been engineered to explore the opportunities for lightweighting by adopting material and design strategies within the interior components. With emerging consumer trends such as infotainment, noise reduction, luxury textiles and electronic air conditioning, interior lightweighting strategies face the challenge of meeting customer expectations, safety standards whilst being financially viable. KEY THEMES TO BE COVERED: OEM STRATEGIES: How OEMs Are Balancing Costs, Carbon Emissions And Customer Expectations To Forge A Successful Interior Lightweighting Strategy COST-DRIVEN SUPPLY CHAINS: Developing Partnership Strategies Between OEMs And Each Supplier Tier To Reduce Cost And Time For Lightweight Design Implementation PLASTICS: Identifying Material And Moulding Innovations To Reduce The Weight And Cost Of Producing Lightweight Plastic Parts LIGHTWEIGHT SEATING: Showcasing Cost Effective Lightweight Materials For Frames And Foams For Seating LIGHTWEIGHTING OF ELECTRONIC PARTS: Assessing Design And Material Selection Strategies To Reduce Electronic Weight NOISE REDUCTION VS LIGHTWEIGHTING: Determining Lightweight Designs And Materials That Can Be Applied For Noise Reduction Functions

1. Part of the GALM series: 1500 attendees, 120+ OEM speakers globally
The first manufacturing-focused GALM event in Europe
18th
-19th
November 2015 | Birmingham | UK
Brand New OEM Case Studies Delivered By:
M Follow us @AutomotiveInnov
www.lightweight-vehicle-manufacturing-europe.com
Dr. Ing. Petra Krammer
Manager Advanced
Manufacturing Technology
Adam Opel AG
Gökhan Dogan
New Projects Stamping Supervisor,
Tool & Die Department
Ford
Dr.-Ing. Markus C. Hahn
Assistant Manager Advanced
Technology & Engineering
Mazda Motor Europe GmbH
Mathieu Kielwasser
Expert In Laser Applications Responsible For
Multi Technology Multi-Material Assembly
PSA PEUGEOT CITROEN
Alexander Wieczorek
Advance Development (EKP/V)
Volkswagen
Felix Schuler
ME Body System
Adam Opel AG
Dr. Dezhi Li
Senior Research Fellow, High Value
Manufacturing Catapult project in WMG
University of Warwick
Reducing The Cost And Complexity
Of High Volume Manufacturing Processes
Multi Material Joining, Forming & Production
For Next Generation Lightweight Vehicles
Reviewing The Latest Adhesives, Mechanical And Welding Techniques To Cost-
And Time-Sensitively Join Multi-Material Architectures
LATEST JOINING TOOLS
Organised by In association with
Unveiling The Moulding Processes Leading The Way In Reducing
Costs And Cycle Times To Allow Widespread Composite Adoption
COMPOSITE PRODUCTION
Leveraging Joining Methods Compatible With Diverse Material Combinations
To Reduce The Number Of Tools And Costs Of Multi-Material Joinings
MULTI-MATERIAL JOINING
How To Adopt New Materials Such As Composites And New Forming And Joining
Tools Into An Assembly Process With Minimum Disruption To Production
ASSEMBLY INTEGRATION
From Design For Manifacturing To Automation And Simulation, Hear
Which Technologies Are Reducing The Cost Of Manufacturing
MANUFACTURING COST REDUCTION
Comparing Methods To Cost-Effectively Create Parts From High
Strength Steel, Aluminium And Magnesium
METAL FORMING
Alberto Palomar
Manufacturing General Manager
Renault - Spain
GROUPDISCOUNTS
&OEMRATES
AVAILABLE
Email info@lbcg.com
Register By Friday
25th
September 2015
SAVE
£200

2. www.lightweight-vehicle-manufacturing-europe.com + 44 (0) 800 098 8489 info@lbcg.com
WELCOME TO THE INAUGURAL LIGHTWEIGHT VEHICLE
MANUFACTURING CONGRESS 2015
A part of the world leading GALM Series coming for the first time to Birmingham
on 18-19th November 2015.
With a specific focus on joining, forming & assembly for lightweight materials
this summit will deliver OEM-led presentations and panel discussions on
reducing the costs and complexity of high volume manufacturing processes with
specific case studies on multi material joining, integration of new technologies
and materials into manufacturing processes, composite production, metal
forming and manufacturing innovations.
Lightweight Vehicle Manufacturing: Joining, Forming & Assembly Summit
will allow the leading experts from OEMs, Tier 1 suppliers and technology
providers to converge to one location to discuss the most critical areas within
manufacturing and assembly processes to enable delivery of next-generation
lightweight materials to the forecourt.
WHAT’S SPECIAL ABOUT LIGHTWEIGHT VEHICLE MANUFACTURING
SUMMIT EUROPE 2015?
PRACTICAL FOCUS: Evaluating new manufacturing processes, joining
and forming technologies for advanced materials that have been applied by
OEMs and their partners to scrutinise what can be adopted in high volumes at
optimal costs and revolutionise vehicle lightweighting
COMPOSITES PRODUCTION EXPANDED: Scrutinising cost optimisation
during the production process and integration of composites into high volume
vehicles
JOINING & FORMING EXPLORED: Benchmarking multi materials joining
solutions and testing them against the key cost and performance parameters
while exploring new cost effective forming methods
MANUFACTURING INNOVATION: Investigating the latest manufacturing
techniques including process automation, simulation and repair to enable
quality assurance for high volumes
NEW CASE STUDIES AND PROVEN METHODS: Participants will benefit
from evaluating the most advanced technologies used and assessing the
effectiveness of innovative methods adopted in the lightweight automotive
production with a chance to apply them in their daily operations to maximize
output and efficiencies
Birmingham Botanical Gardens
Westbourne Road
Edgbaston
Birmingham
B13 3TR
Tel: 0121 450 4607
Web: www.birminghambotanicalgardens.org.uk
To enquire about speaking opportunities,
secure your booth or discuss tailor-made
sponsorship packages, contact:
Ashley Barnes
Group Commercial Director
Email: ashley.barnes@lbcg.com
Tel: +44 (0) 20 3727 3148
Venue Information: Sponsorship Opportunites
Register By Friday
25th
September 2015
SAVE
£200

3. REDUCING THE COST OF MULTI-MATERIAL JOINING, COMPOSITE PRODUCTION
AND INTEGRATION INTO ASSEMBLY STRATEGIES
Day 1
Wednesday 18th
November 2015
• Understanding the opportunities with fasteners and
direct joints
AndreasLembach,InternationalWeldingEngineer,Engineeratthe
TechnicalDevelopment,PROFILVerbindungstechnikGmbH&
Co.KG
11.05 Question & Answer Session
11.10 Morning Refreshments In Exhibition Showcase Area
MAGNESIUM JOINING
11.40 Exploring Tools To Significantly Reduce Costs
And Eliminate Corrosion When Joining Magnesium
With Other Lightweight Materials
• Evaluating the optimal joining techniques for joining
magnesium with other lightweight metals such as
high strength steel and aluminium
• Determining what can be done at the level of joining
to prevent corrosion when dissimilar materials come
into contact
• Identifying which joining techniques offer the optimal
time- and cost-efficiencies for each magnesium
combination
• Learning what success OEMs have had joining
magnesium with composites: What are the
challenges?
12.10 Question & Answer Session
ROUNDTABLE: ADOPTING OPTIMAL JOINING TOOLS
12.20 Benchmarking The Flexibility Of Each Joining
Method To Choose Which Limited Number Of Tools
Should Be Adopted On The Assembly Line
• Exploring the material selection and joining
principles that have been adopted in the latest
MMLVs in Europe
• Defining steps adopted by OEMs and partner to
develop manufacturing strategies that enabled
effective and cost efficient multi-material vehicle
assembly
• Learning about the methodology used to select
joining methods based on the material application
and the required adjustments to assembly
infrastructure
• Conducting financial life cycle assessment of the
MMLVs and associated joining techniques when
transitioning into fewer configurations
ChairedBy:Dr.-Ing.MarkusC.Hahn,AssistantManager,Advanced
Technology&Engineering,MazdaMotorEuropeGmbH
Dr.PhilVadillo,AdvancedTechnologyResearch(ATR)BlockDeputyATR
BlockManager,StaffEngineer,HondaEngineeringEuropeLtd.
12.50 Networking Lunch In The Exhibition Showcase Area
COMPOSITE PRODUCTION
Revealing The Latest Breakthroughs In High Volume
Production Techniques For Carbon And Glass-Fibre
Reinforced Plastics
COMPOSITE PRODUCTION COST REDUCTION
1.50 Hearing Case Studies On OEMs That Sourced
Affordable Carbon Fibre, Formed CFRP Parts And
Joined Into Mass Produced Vehicles
• Learning how some OEMs went about identifying
their suppliers to establish robust supply chains for
carbon fibre
• Evaluating processes being applied and technologies
adopted for mass production of carbon fibre parts:
Scaling production from the thousands to the
hundreds of thousands
• Understanding how the production and joining
methods applied protected the material properties
through manufacturing
• Learning about the potential of using structural
composites for load bearing parts to gauge their
application in crash bearing areas
Dr.NickWarrior,ProfessorofMechanicalEngineering,
FacultyofEngineering,UniversityofNottingham
2.20 Question & Answer Session
CARBON-FIBRE COMPOSITE PRODUCTION
2.30 Identifying Which Moulding Techniques Are
Leading The Way In Consistently Producing High
Volume Glass and Fiber Composite Parts
• Spearheading manufacturing processes for
composites which minimise labour involvement
such as infrastructure adjustments and process
automation
• Learning how to bring the composites solutions
available today to a low cost base to make it suitable
for an OEM’s price production point
• Reviewing the consistency and cycle time of
composite production to determine appropriateness
for high volume applications
• Exploring composite material properties and costs
to identify their optimal applications in lightweight
vehicles
3.00 Question & Answer Session
3.10 Afternoon Refreshments In The Exhibition Showcase Area
INTEGRATION
Strategies For Integrating New Materials And Technologies
Into The Manufacturing Process With Minimal Disruption
NEW TECHNOLOGY INTEGRATION
3.40 Spearheading Cost Effective Integration Of
New Manufacturing Technologies Into A Plant With
Minimum Interruption To Operations
• Understanding how the integration strategy of
manufacturing technologies varies based on the
production volumes expected and how does the
innovation improves quality
• Collaborating between OEMs and technology
suppliers to minimise disruption to the production
line
• Understanding new and old processes and
comparing them against the key parameters
• Learning how the innovation has proven to increase
profitability of operations
4.10 Question & Answer Session
PANEL DISCUSSION: COMPOSITES - OUTSOURCE VS.
PRODUCE IN HOUSE
4.20 Hearing OEM Views On The Economies Of
Scale And Business Case For Restructuring To
Accommodate Composites
• Debating the benefits and consequences of pressing
composite parts in-house vs. outsourcing: costs
and risks
• Examining how to restructure business models to
make outsourcing cost efficient and robust
• Making adjustments to the business model
to accommodate composites with maximum
profitability
ChairBy:Dr.-Ing.MarkusC.Hahn,AssistantManager,Advanced
Technology&Engineering,MazdaMotorEuropeGmbH
4.40 Chair’s Closing Remarks
4.50 - 5.50 Networking Drinks In The Exhibition
Showcase Area
MULTI-MATERIAL JOINING
Reducing The Complexity And Cost Of Multi-Material
Joining On The Assembly Line For Each Material
Combination
8.30 Chair’s Opening Remarks
SessionChair:Dr.-Ing.MarkusC.Hahn,Assistant
Manager,AdvancedTechnology&Engineering,MazdaMotor
EuropeGmbH
KEYNOTE: MULTI MATERIAL JOINING SIMPLIFICATION
9.00 Reducing Complexity And Cost Of Multi-Material
Joining: Identifying Flexible Tools Compatible With
Composite/Metal Combinations
• Understanding influence of the regulation
context on the design and the multi
material contribution to vehicle lightweighting
• Evaluating which tools are compatible with each
popular material combination to determine flexibility
and total cost of integrating into the assembly
• Overcoming multi-material joining complications
such as varied temperature range, galvanic corrosion
and stress transfer issues
• Examining the existing multitude of multi-material
joining solutions to identify which requirements do
OEM have with respect to composite/metal joining
MathieuKielwasser,ExpertInLaserApplicationsResponsible
ForMultiTechnologyMulti-MaterialAssembly,PSAPeugeot
Citroen
9.30 Question & Answer Session
SURFACE TREATMENT OF HOT STAMPED STEEL
9.50 Examining Laser Surface Treatment Of Hot
Stamped Steel To Enhance Bonded Joints
• Understanding failure modes of aluminum-silicon
coated hot-stamped steel for BIW application when
hot stamped steel is bonded and a peel force is
applied to the joint
• Learning about the application of the laser process
before bonding, to increase transferable force and
the energy-dissipation
• Examining the benefits, including safety
improvement when hot stamped steel and adhesives
is combined
AlexanderWieczorek,AdvanceDevelopment(EKP/V),
Volkswagen
10.20 Question & Answer Session
MULTI MATERIAL JOINING
10.30 Evaluating Different Joining Techniques To
Understand Which Can Deliver The Most Cost And
Time Effective Solution For Mixed Material Joining
For Lightweight Vehicles
• Evaluating the optimal joining techniques for when
you have steel, aluminum and carbon fiber in the
same car
• Determining what can be done at the level of joining
to prevent corrosion when dissimilar materials come
into contact
• Determining which joining techniques offer the
optimal time- and cost-efficiencies for mixed
material applications
• Overcoming the key challenges of optimizing mixed
material joining techniques at mass produced scales
CraigCowan,President,RB&W
10.45 Question & Answer Session
MECHANICAL JOINING OF COMPOSITES
10.50 Understanding the Mechanical Joining of
Composites in High Volume Production
• Examining joining of thermoplasitc materials
• Exploring the joining methods for
thermosetting material
• Learning about the specifics of hybrid material to
identify optimal joining method
www.lightweight-vehicle-manufacturing-europe.com + 44 (0) 800 098 8489 info@lbcg.com

4. REVEALING THE LATEST METAL FORMING TECHNIQUES, ADVANCES IN POPULAR JOINING
TOOLS AND OPPORTUNITIES FOR RAMPING UP ASSEMBLY EFFICIENCY
Day 2
Thursday 19th
November 2015
• Analysing the safety considerations of handling
magnesium and identifying methods to mitigate
risks during forming processes
10.40 Question & Answer Session
10.50 Morning Refreshments In The
Exhibition Showcase Area
JOINING
Examining Ways To Cost Effectively Apply Adhesive
Bonding, Self Piercing Riveting And Welding Methods In
Multi Material Architectures
SELF-PIERCING RIVETS
11.30 Examining The Potential of SPRs In Cost-
Effectively Joining Parts, Maintaining Joint Strength
And Reduce Overall Cycle Times In Multi Material
Applications
• Learning about the advantages and disadvantages,
including meeting the cycle times requirements with
the application of SPRs
• Examining current and future manufacturing
strategies using SPRs and their application in
automotive industry
• Mapping mechanical fastening options to benchmark
performance vs. costs of the available solutions in
comparison to SPRs
• Hearing how reliable SPR process is in multi-
materials joining: How often do problems occur?
Dr.LiDezhi,Sr.ResearchFellow,HighValueManufacturingCatapult
projectinWMG,UniversityofWarwick
12.00 Question & Answer Session
CHALLENGES JOINING A MULTI-MATERIAL BODY
12.10 Improving Reliability of Joining Multi-Materials
at Higher Volumes - Work at the UK High Value
Manufacturing Catapult
• Reviewing UK high value manufacturing project
catapult to understand its role in improving
manufacturing processes for lightweight vehicles
• Examining challenges raised by light-weight and
high strength automotive materials at high volumes
• Mapping the existing types of adhesives to understand
the variety and applicability to different materials
• Assessing the importance of surface condition in
adhesively bonded joints
DrDarrenJ.Hughes,AssistantProfessorinMaterialsand
Manufacturing,WMGCentreHighValueManufacturing
Catapult,UK
12.40 Question & Answer Session
12.50 Networking Lunch In the Exhibition Showcase Area
WELDING
1.50 Learning The Latest Advances In Laser And Spot
Welding To Reduce The Cost Of Joining Lightweight
Metals For Mass Production
• Comparing welding methods for popular material
combination based on material type, cost, cycle time
and joint performance
• Comparing laser and spot welding techniques to
select the most suitable for different material and
structural applications
• Hearing how welding technologies can be made
compliant with the existing structures without
building up an accompanying new plant
• Reviewing the flexibility of welding to join diverse
material combinations to simplify the overall
assembly process
2.20 Question & Answer Session
MANUFACTURING INNOVATION
Learning The Latest Manufacturing Techniques Including
Design For Manufacturing, Process Automation & Simulation
To Enable Consistency In Production Of Quality Parts
In High Volumes
PANEL DISCUSSION: MANUFACTURING PROCESSES
FOR VEHICLES OF 2025 - 2030
2.30 Debating Which Manufacturing Technologies And
Processes Are Currently Under Development And Will
Be Available To Use For Vehicles Of 2025-2030
• Bringing different technologies into perspective
to evaluate which has the most potential in being
applied to vehicles of 2025-2030
• Hearing thoughts of the panellists on what the
R&D focus should be in order to make substantial
progress in cost reduction
• Assessingwhatbrandnewtechnologicaladvances,
currentlystillinthetestingphase,couldhelptoindustrialise
lightweightjoiningandforminginthenext10years
• Exploring opportunities with new materials, changes
in vehicle design and manufacturing process to take
further substantial weight out of the vehicle with
minimum investment required
ChairedBy:Dr.Ing.PetraKrammer,ManagerAdvanced
ManufacturingTechnology,AdamOpelAG
3.00 Afternoon Refreshments In The
Exhibition Showcase Area
DESIGN FOR MANUFACTURING
3.30 Integrating Manufacturing Insights Into The
Design Process To Ensure Production Costs And
Times Are Factored In From The Initial Stages Of
Product Development
• Establishing strategies to enable effective
collaborations between design and manufacturing
departments to test manufacturing feasibility of the
selected material
• Evaluating tools to examine limitations of
manufacturing processes to help designers create
parts that are actually needed
• Learning about design for manufacturing practices to
minimize production cost and optimize quality of a part
• Hearing what training strategies are used to give
designers greater insight into manufacturing
limitations and realities
DanFord,GroupLeaderCoreTechnology,BodyCompleteBusinessUnit,
JaguarLandRoverProductDevelopment
4.00 Question & Answer Session
PROCESS SIMULATION
4.10 Leveraging Simulation Tools To Predict The
Impact Of Production And Joining Methods On The
Properties Of Lightweight Materials
• Learning about the use of process simulation
methods during design to avoid costly
trial-and-error prototyping
• Understanding whether simulation of the production
performance can be applied before a new process
is in line
• Scanning the process capability to monitor and
provide the information on the repeatability and
reliability of the process
• Evaluating the performance of the process to
validate that the processes applied are good and to
required strength
4.40 Question & Answer Session
4.50 Chair’s Closing Remarks
5.00 End Of Congress
DayChair:Dr.PetraKrammer,ManagerAdvanced
ManufacturingTechnologies/MES&P,AdamOpelAG
8.30 Chair’s Opening Remarks
Breakfast Briefing
MANUFACTURING QUALITY CONTROL
8.40 Utilizing Hand Held XRF (X-Ray Fluorescence)
To Confirm The Chemical Composition Of Aluminum
And Other Alloys to Ensure Quality Control Over The
Materials Throughout Automotive Manufacturing
• Including the role of XRF to accurately measure
the thickness of electro plating, passivation and
conversion coatings
• Assessing the compatibility of XRF to measure the
chemical composition of High Strength Steels,
Magnesium and Titanium alloys
MarkLessard,BusinessDevelopmentManager,
ThermoFisherScientific
METAL FORMING
Revealing The Most Cost Effective Forming Methods For
Each Material To Maximize The Weight Saving Potential Of
Each Part
KEYNOTE: METAL STAMPING
8.50 Overcoming Stamping Concerns While Stamping
High Strength Steels and Aluminium Panels
• Examining existing tool manufacturing timings, cost
reduction opportunities and material utilization rates
• Scrutinising relation between the tool and panel
quality to identify opportunities for improvement
• Reviewing case studies on stamping tools for High
Strength Steels and aluminium
• Mapping out major issues while stamping aluminium
panels and devising future stamping strategies
GökhanDoğan,NewProjectsEngineeringTeamLeader,Ford
9.20 Question & Answer Session
SPRINGBACK COMPENSATION OF ADVANCED AHSS
9.30 Devising Methods For Effective Springback
Compensation of Advanced High Strength Steels
• Understanding problems associated with high
strength values of AHSS and identifying ways to
eliminate the limitations for the wider use of AHSS
• Definition of a prototype tool geometry and validation
of the forming simulation and the impact on crash
• Learning about the automatic Radii optimization tool
and further steps at GM
FelixSchuler,MEBodySystem,AdamOpelAG
10.00 Question & Answer Session
MAGNESIUM FORMING
10.10 Exploring The Latest Cost Reductions And
Performance Improvements In Magnesium Castings
To Enable Mass Adoption
• Comparing the current cost of magnesium forming
with other material processes to determine viability:
At what cost will magnesium casting be viable for
mass production?
• Hearing how magnesium casting advances have
improved temperature range, cycle time and
component performance
• Appraising material performance with consideration
to uniformity, porosity and cavity during
manufacturing
www.lightweight-vehicle-manufacturing-europe.com + 44 (0) 800 098 8489 info@lbcg.com

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