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Dana Corporation Demonstrates Manufacturing Flexibility with Toyota Tundra Frame TOLEDO, Ohio, Nov. 13 /PRNewswire-FirstCall/ -- Dana Corporation's 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 flexibility." 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/ . http://www.newscom.com/cgi-bin/prnh/19990903/DANA http://photoarchive.ap.org/ DATASOURCE: Dana Corporation CONTACT: Jeff Cole of Dana Corporation, +1-419-535-4704, or email, Web site: http://www.dana.com/ Company News On-Call: http://www.prnewswire.com/comp/226839.html

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