Jaguar uses castings, extrusions to reduce parts count in new sports car

Purpose - Describes how Jaguar Cars in the UK is assembling aluminium car bodies for its new XK sports car that will be manufactured with a production time of 12 hours. Design/methodology/approach - Describes the major production line techniques that are used in the assembly of the body-in-white structure. These include adhesive bonding, self-piercing rivets (SPRs) and self-tapping screws. Findings - The use of SPRs and self-tapping screws is proving essential in the joining of aluminium components manufactured as extrusions, castings and pressings. Research limitations/implications - The introduction of adhesive bonding, SPRs and self-tapping screws is the result of considerable research work on the part of Jaguar engineers and the company's suppliers. This work is likely to continue in order to reduce cycle times and improve overall product performance, both in terms of manufacture and for the user. Practical implications - It is likely that arising out of development work into new assembly techniques that the technology will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Both Aston Martin and Volvo could benefit from the technologies developed at Jaguar Cars. Originality/value - This is the first time that Jaguar Cars has used self-tapping screws to join aluminium components although it has been used before within Lotus Group for the Elise sports car.