gkn at a glance · 11:00 – 12:00 plant tour/plant 1 mike erdt 12:00 – 1 ... gkn aerospace...
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2
Agenda
9:00 – 9:15 Meet & Greet Bob Willig
9:15 – 10:15 GKN & Torque Presentation Bob/Jochen
10:15 – 10:45 Break All
10:45 – 11:00 PPE Mike Erdt
11:00 – 12:00 Plant Tour/Plant 1 Mike Erdt
12:00 – 1:00 Lunch All
1:00 – 2:00 Plant Tour/Plant 2 Mike Erdt
2:00 – 2:30 Wrap Up Bob Willig
3
Every day at GKN,
we drive the wheels of hundreds of millions of cars,
we help thousands of aircraft to fly,
we deliver the power to move earth and harvest
crop and we make essential components for
industries that touch lives across the globe.
4
GKN Driveline GKN Powder
Metallurgy
World leader in the
manufacture of sintered
components
Manufactures precision
automotive, industrial
and consumer products
Largest powder
producer in North
America
GKN Aerospace
Supplier to the global
aviation industry
Leader in the
manufacture of highly
complex composite
aero structures and
engine products
Developer of fuel
efficient solutions to
lower emissions
GKN Land Systems
Supplier to the global
agricultural,
construction, mining
and other industrial
markets
Innovation within
renewable energy and
mass transit solutions
Global aftermarket
distribution and service
World leading supplier
of automotive driveline
systems & solutions
Focused on solutions
that create weight,
space and fuel savings
Committed to
innovation
GKN at a glance
5
GKN at a glance
49,700 people
Global footprint – 40 countries
Market leading businesses
Above market growth
Operational excellence
GKN Driveline
GKN Powder
Metallurgy
GKN Aerospace
GKN Land Systems
Other
GKN 2013 Sales
£7.6bn $US 12.7bn €9.1bn
7
GKN Driveline
Largest business of global engineer GKN
Market leading driveline technologies
• CVJ Systems
• AWD Systems
• Trans Axle Solutions
• eDrive Systems
Broad global footprint
Established long term global relationships
Focused engineering resource providing
driveline solutions
Expert customer specific account teams
8
GKN Driveline Executive Team
Regions
Chief Executive
Andrew (Andy) Reynolds Smith
Functions
Senior Vice President –
Finance and IT
Bill Curral
Senior Vice President –
Engineering
Rob Rickell
Senior Vice President –
Lean Enterprise and
Manufacturing Engineering
Marc Vuarchex
Senior Vice President –
Quality and
Risk Management
Trevor Pillay
Senior Vice President –
Commercial and
Customer Management
Stefan Magirius
Senior Vice President –
Purchasing and
Supply Chain
Philippe Roman
Senior Vice President –
Human Resources
Monique Carter
Senior Vice President –
Program Management
and Strategy
James (Jim) Voeffray
President – Americas
Robert (Bob) Willig
President – Europe
Helmuth Rohregger
President – Asia Pacific
Arnaud Lesschaeve
9
GKN Driveline – Sales 2013
Europe 37%
Asia Pacific
27%
Americas 36%
Trans Axle Solutions
7%
eDrive Systems
1% Other 1%
CVJ Systems
62%
AWD Systems
29%
by product segment by region of origin
£3,416m US$5,699m €4,106m
10
GKN Driveline – Sales 2013
VW 15%
GM Group 12%
Fiat Chrysler 11%
Ford Group 11%
Renault-Nissan
10% Toyota Group
6%
Tata Group 5%
BMW 4%
Mitsubishi Group 4%
Volvo Cars 4%
Other 18%
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Brazil
India
U.K.
France
Spain
Italy
Slovenia
Turkey
Malaysia
Thailand
Colombia
Singapore
Taiwan
Japan
United
States China
South
Korea
Australia
Mexico
Sweden
Poland
Germany
GKN Driveline – An Excellent Global Footprint
Manufacturing plant
Joint Venture
Corporate office /
Engineering centre
GKN Driveline
end-2013
£3.42 billion
Sales
c.24,000
Employees
45 Manufacturing Plants
22 Countries
12
GKN Driveline – 4 Strong Product Segments
CVJ Systems AWD Systems Trans Axle Solutions eDrive Systems
CV Joints
Sideshafts
Propshafts
Transfer Units
AWD Couplings
Disconnects
Final Drive Units
Differentials
Limited Slip &
Locking
Differentials
eAxles
eTransmissions
eMotors
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High performing, economic
solutions
Twinball (ST) joint with Face Spline
50% higher torque transfer
54 degree articulation – tightest
turning
reduced assembly time & backlash
Maximised performance
Ballspline system
maximise offroad angle & movement
Reduce NVH
GKN Driveline – CVJ Systems
Fuel saving technology
countertrack™ CVJ
smallest
lightest
most efficient
High performing, economic
solutions
Twinball (ST) joint with Face Spline
50% higher torque transfer
54 degree articulation – tightest
turning
reduced assembly time & backlash
efficient thinking The technology leader in CVJ sideshafts
Weight, space and fuel savings
Improved efficiency
Solutions provider
Most extensive range of CVJs
Widest global footprint
Manufacturing CVJs in 20 countries
14
GKN Driveline – AWD Systems
The global leader in efficient all-wheel
drive systems
Unique capability to develop and
manufacture full AWD Systems
World-class engineering over many
years
Optimized components through full
system understanding
dynamic thinking Reduces everything but
performance
DTF propshaft interface
reduces weight
reduces assembly time
reduces packaging space
reduces system costs
AWD Disconnect
Power Transfer / Rear Drive Unit
seamless engagement to AWD
mode
no compromise all wheel drive
improved efficiency
expert all wheel drive capability
Performance AWD
TWINSTER®
disconnect and LSD combination
efficiency and performance
active yaw control
optional torque vectoring
High performance coupling
EMCD®
electric or hydraulic actuation
low drag torque
Optimised connection methods
15
GKN Driveline – Trans Axle Solutions
Global supply
Open Differential
smaller packaging
weight saving
globally available
Improved dynamic performance
Electronic Torque Manager (ETM®)
maximum traction
maximum stability
Adaptable sophisticated
technology
Electronic Torque Vectoring
controlled fast cornering for premium
cars
Off-road expert
Electronic Locking Differential
fast locking rear axle for extreme off-
road conditions
unlimited thinking A leader in conventional and controlled
differentials for transmissions and axles
Manufacturing in all regions of
the world
Full product range
Established and experienced player
16
GKN Driveline – eDrive Systems
Electrified thinking A pioneer in advanced electric and
hybrid drivelines
Systems leadership capability
Standard product range
250,000 vehicles on the road
eTransmissions success in each
major automotive region
Broader range of motors
Hybrid with improved
performance
eAxle System
30% fuel saving
four driving modes
Economies of scale
eTransmission Family Approach
Compact
ultra quiet
choice of interfaces & gear ratio
Proven technology
Multi-mode eTransmission
total control of fuel economy
seamless switching between modes
Dynamic partnership
Integrated Motor & eTransmission
advanced electric motor technology
low weight
compact packaging
CVJ Systems
AWD Systems
Trans Axle Solutions
eDrive Systems
GKN Driveline Americas Torque Business Unit
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Torque Business Unit
Bowling Green, OH Newton, NC Auburn Hills, MI
Transaxle Solution Electronic Locking Differentials
Open Differential
Torque Management Devices /
Clutches
AWD Systems Final Drive Units
Power Take-off Units
Rear Drive Modules
AWD Disconnect
Systems
Technical Center Product Engineering
Program Purchasing
Top Line Progression
21
Plant Director
NWT
Mike Erdt
Plant Director
BGR
Craig Zimmerly
Purchasing
Director
Todd Tinnell
Director of Program
Management
Markus Herrmann
Director Product
Technology
Edward Kwon
Business Analysis
Director
David Wilson
Program Director
GM AWD
Brad Murphy
Finance
Director
Kevin Ruff
Human Resources
Director
Kimberly Byerley
Commercial
Director
Owen Nagy
VP Operations AWD
& Transaxle Solutions
Jochen Wieland
Operations Functions
President .
Americas .
Bob Willig .
Our Team
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GKN Driveline Newton
248,000 Sq. Ft. / 23,038 m²
Central Administration
Spiral Bevel Gear, Housing and Cover Production
Assembly
Plant 1
257,000 Sq. Ft. / 23,876 m²
Logistic Services
Assembly
Axle Development Lab
Plant 2
Location: Newton, North Carolina
784 Employees as of October 2014
Total Sq. Ft. 505,000 / 46,914 m2
37
Lead in Chosen Markets
Focus on AWD systems, Premium FDU’s, EDL, Clutches
Clutches provide
most of growth
– GM D2
Considerable growth
on FDU’s
– BMW Front FDU
– Mercedes Front
FDU (KBO)
39
Leverage Global Footprint
Localize Gear-Set manufacturing
28% of all gearsets
used are currently
imported from:
– Tochigi for
Chrysler MK
– Koeping / Nagoya
for GM Lambda
PTU
– BMW DGF
40
BMW
Chrysler
Ford
GM
Mercedes
Subaru
2.47 mio
units1.19 mio units
2014 2019
Leverage Global Footprint
Localize Gear-Set manufacturing
Localization and new
business wins help
to diversify
distribution to a
more robust
business case for
the high capex gear-
set manufacturing
area
41
Global Mega Platforms - ‘Go East to win the West’
Large and Mega Platform revenue will be over 80% of total revenue for Torque
Global Footprint and global capabilities will be a decisive factor for sourcing by the OEM’s, GKN needs to
strengthen it’s global organisation in regards to:
Commercial
Program Management
Manufacturing Systems
Engineering
Purchasing / Supply Chain
Revenue Growth on Large
and Mega Platforms % to Total Revenue
43
Technology Driving Margins
Disconnect systems, Clutches, EDL, ECU incl. Software
Example Lambda RDM and PTU C1UX AWD System
GKN Content: – Assembly
– RDM Gear-
set
GKN Content: – Assembly
– RDM & PTU
Gear-set
– PTU
Disconnect
system
– Single /
Twin
hydraulic
Clutch
– GKN ECU &
Software
Approx. $850 Approx. $1,050
Big increase in complexity
and scope requiring new
skills (hydraulics, software,
electronics, ..)
Current State Future State
44
Technology Driving Margins
Disconnect systems, Clutches, EDL, ECU incl. Software
Example Ford C520 Global RDU Ford C2 ETM
GKN Content: – Assembly
– Machining
of Diff hsg
GKN Content: – Assembly
– GKN ECU &
Software
Approx. $35 Approx. $200
Current State Future State
Could open door to
complete RDU
46
Operational Excellence
Strong Focus on
People Development
Engagement
Business Process Improvement
Lean Fundamentals
to drive CI Culture
47
Operational Excellence
However beautiful the
strategy, you should
occasionally look at the
results.
Winston Churchill
48
Operational Excellence
Integrated System for
high level business and
departmental KPI’s,
linked to
– Individual CI plans
– Departmental PVD boards
– PDP goals
50
Sustain Growth Above Market
Focus on Strategic Products
Strategic Products
only!
Internal clutches are sold as
part of a FDU
Twin systems are counted
as two units
units
53
Gear Development Gear Calculation
Prototyping and
Validation
Noise Correlation
Production Support
Warranty / Reliability
Process Improvement S+ Tool Life
$0.670
$0.000 $0.203 $0.238 $0.238 $0.196 $0.224$0.000 $0.000 $0.000 $0.000 $0.000
$0.254
0.350
$0.380
$0.000
$0.100
$0.200
$0.300
$0.400
$0.500
$0.600
$0.700
$0.800
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec YTD
Co
st/P
cs
Actual Forecast
-$21,195 $23,741 $11,955 $7,575 $8,131 $7,387 $6,712
q p p p p p p
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
7.00%
2009 YTD 2010 YTD 2011 YTD
Teststand FTT Fail
Teststand Scrap
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
7.00%
1st Quarter 2nd Quarter 3rd Quarter
648/646V Teststand Scrap
PTU Teststand Scrap
Area’s influenced by the Axle
Development Department
54
Spiral Bevel Gear Manufacturing Ring and Pinion Soft Turning
100% Process Measurement w/ Machine Monitoring for Critical Dimensions
Spline & Thread Rolling
100% Camera Monitoring
Gear Tooth Generating
KIMOS feedback loop for predicative material distortion effects
Vacuum Gas Carburizing Heat Treat
Propane Atmosphere with Nitrogen Quench
Part Specific Heat Treat Recipe
Environmentally friendly – No waste quench oil
Pinion Journal Grinding
In-process Machine Feedback w/ 100% Post Process Gaging
Pitch Chuck Clamping
Ring Hard Turn & Drill
Pitch Chuck Clamping
Hard State – Turning Drilling, and Threading
100% Post process Bore Gaging
Lapping and Testing
100% Measurement and Recording of Run-out, Drive and Coast MTE 1st and 2nd Order.
55
Machining Centers Manufacturing
PTU & RDM Housing Machining
High Speed 5-Axis Single and Twin Spindle Automated Machining
Integrated 2nd Operation - Single Spindle Machining for drain holes and removal of clamping tabs,
Washing, and Leak Testing
Dimensional Gage Stations - 100% measure critical dimensions and mark housings w/ measurement
and traceability information used by Assembly.
PTU & RDM Cover Machining
High Speed 5-Axis Vertical Single Spindle Automated Machining
Automatic Fixture Clamping with air confirmation error proofing to assure part is clamped properly.
56
Laserwelding
High precision CO2 TruFlow Laser Welding process
Force and Distance controlled press process prior to welding – Input Shaft to
Ring Gear
In process monitoring system and data tracking through Gear Set Number
Mini Lab for frequent quality checks during production – batch control
Laser Cell prepared with Wire Feed to be able to implement Differential Welding
(Cast Iron)
57
Less complex Single Station concept to
improve uptime
Rework and material inside the loop for
optimal space utilization
Quick Change over
Minimized foot print
Operator friendly design
Manpower flexible
100% Data tracking
High amount of error proofing
70 sec cycle time, with easy upgrade to
50sec
Decoupled test stand motor (belt drive) to
minimize influence on NVH test
Independent EOL loop from Assembly
High Volume Assembly – New Generation
58
ISO/TS 16949:2009
EN/ISO 14001
OSHAS 18001:2007
CQI-9 Certified
Six-Sigma and Red X trained staff
GM-Quality System Basics
Fully equipped Metrology Lab
Fully equipped Metallurgical Lab
On site incoming inspection facility
On site supplier quality support group
Quality Certifications and Capabilities
59
Supply Base
3PL’s
GAP
Collaborative Web-Based supply chain management tools
Supply Chain Synchronization / Pull Replenishment
Real Time data sharing
Freight cost/unit down during inflationary fuel cost periods
Year-over-year Inventory Reductions
Supply Chain Management / Logistics Execution
60
SAFETY REQUIREMENTS FOR VISITORS
Requirements:
• All visitors must wear
GKN Safety Vest when
entering shop floor area
• All visitors must wear
safety shoes (steel or
composite toe) when
entering the shop floor
• All visitors must wear
safety glasses
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