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Gear Shift System

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  • 1DURA Shift Systems Overview

  • 2Technology ReviewProduct Portfolio

    Leather and Wood Grain KnobsPaint and Chrome Bezels Electronic IndicationElectronic Brake and Key InterlockStraight and Cross-over Gate Styles

    Transfer Case and Body Mount ApplicationsIntegrated With Automatic Shifter

    With and Without Overdrive Cancel SwitchTwo-shot Overmolded KnobsPress-fit KnobsTube and Gun-drilled Rods for Wire Harness Routing

    Floor and Direct Mount (to Gearbox) ApplicationsLeather Knobs and BootsExtensive NVH Isolation Engineering

    Diecast Housing ConstructionIntegrated Shift Cables

    Floor ATX Floor MTX Transfer Case Column Mounted ATX

    IP Mounted

  • 3Kevin MartinDirector of Operations

    Mechanical Assemblies(904) 268-8301

    David KleinSales Director

    Park Brakes N.A.(248) 299-7619

    Tom PetersEngineering Director

    Park Brakes N.A.(231) 587-0248

    John TruckeyV.P. / General Manager / Director OperationsPark Brake, Pedals & Mechanical Assemblies

    (231) 587-0262

    David McClureDirector of Operations

    Cables(573) 248-8563

    David HenleyPlant Manager

    Brantford, Ontario(519) 756-1650 x-226

    Joel NewstedPlant ManagerFremont, MI

    (219) 592-1702

    Dan StraitEngineering Director

    Shifter Systems(248) 299-7626

    Derrick RyanEngineering Director

    Cables(248) 299-1688

    Tim StephensV.P./ General Manager / Director Operations

    Shifter Systems & Cables(231) 592-1816

    Dean BurchiSales Manager

    Shifter Systems N.A.(248) 299-7659

    Sean O'RourkeSales ManagerCable Systems(248) 299-7571

    Dave BlaszczakSales Director

    Shifter Systems N.A.(248) 299-7612

    Tim GlockVice President

    Sales - N.A.(248) 299-7512

    Dave LesterSales Director

    New Domestics N.A.(248) 299-7562

    Clifford SomervilleVice President

    New Domestics - Global(248) 299-7590

    Milt KnissPresident

    Control Systems Division(231) 587-0213

    Larry DentonPresident & Chief Executive Officer

    (248) 299-7510

    August 2004

    Control Systems - North America

  • 4Dura Shifter Business Overview Technology Review

    Largest Producer of Automotive Gearbox Shift Systems Globally

    Complete Shift System OfferingLevers, Cables, BracketsAutomatic and ManualShift-By-Wire ApplicationsConsole, Column and IP Mounted Packages

    Vertically IntegratedElectronics Design and DevelopmentLever Machining, Gun-DrillingInjection Molding (integrated with assembly cell)Flexible Cellular ManufacturingState of the Art Injected Foam Molding of Knobs

    Complete Product Development CapabilitiesComplete CAD/CAE CapabilityComplete in-house Testing Durability, NVH, Corrosion, etc.

  • 51

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    5

    1 2 3 4 5

    1

    2

    3

    4

    5

    1 2 3 4 5Competitive Position

    Tech

    nica

    l Cap

    abili

    ty

    Market Position Technology Review

    DuraTokai Rika

    GHSPSamlip

    Teleflex

    Ficosa

    NA (ATX)

    Sales

    Market Share

    Competitive Analysis

    Europe (MTX)

    DuraTeleflex

    Ficosa

    SilaIn-House

    Dura 18%

    Teleflex8%

    GHSP24%Tokai Rika

    10%

    Samlip7%

    Ficosa6%

    Other27%

    Delphi11%

    Ford34%

    General Motors20%

    DaimlerChrysler33%

    CAMI1%

    Ada1%

    In House27%

    Teleflex17%Fico

    8%

    Dura25% Other

    7%Sila9%

    Cimos5%

    W oco1%

    Lemfoerder1%

    In House27%

    Teleflex17%Fico

    8%

    Dura25% Other

    7%Sila9%

    Cimos5%

    W oco1%

    Lemfoerder1%

    Sale s by Custom er 2002

    VW31%

    BMW5%

    For d17%

    G M4%

    Renau lt8%

    PS A10%

    Others8%

    IN CO8%

    Tier I9%

    Porsche0.6%

    Sale s by Custom er 2002

    VW31%

    BMW5%

    For d17%

    G M4%

    Renau lt8%

    PS A10%

    Others8%

    IN CO8%

    Tier I9%

    Porsche0.6%

  • 6Escort, Mustang, Taurus, Crown Vic, F-Series, Explorer, Expedition, Ranger, Freestar, Focus, Mondeo, Fiesta, Ka, Puma

    Sable, Mountaineer, Marauder, Montego

    Aviator, Navigator, Town Car

    X-Type

    Grand Prix, Monte Carlo, Vectra, Corsa, Saab 93, Cavalier, Sunfire, Corvette, Venture Montana, Silhouette, Rendezvous, Trailblazer, Envoy, Hummer 2, Silverado

    Intrepid, Neon, PT Cruiser, Minivan, Stratus, Sebring

    Grand Cherokee, Liberty, Wrangler

    Tundra, Sequoia

    Polo, Golf, Passat, Beetle, Sharan, A2, A3, A4

    Avantime, Velsatis, Laguna, Espace, Traffic

    Picasso, 807, 407, 106/Saxo

    Customer Portfolio (Current Business)

    A-Class

    Pilot, Odyssey

  • 7Technology ReviewEngineering Capabilities

    CAD/CAE CAPABILITYIn-House CAD

    Catia V4/5UnigraphicsIdeas

    ICEM SurfacingComplete FEA Capability

    Linear and Non-Linear Tolerance Analysis Simulation

    ENGINEERING SUPPORTJapan Kariya (Tsuda)U.S. Rochester Hills, MI Technical Center (80Km from Ann Arbor)Europe Einbeck, Germany

    PRODUCT VALIDATIONIn-House Test CapabilityComputer Controlled Test Stands-40 120C Temperature ConditioningAnechoic Chambers (sound room)

  • 8In-House Electronics Capabilities

    ECU Design and Development

    Embedded Software Design

    ESD Controlled Environment

    Surface Mount Component Board Soldering

    S H I F T E R P R O F I L ES H I F T E R P R O F I L E

  • 9Rochester Hills, Michigan (Technical Center)Fremont, Michigan Brantford, Ontario, CANDura Ganxiang, Shanghai, China

    Processes/Capabilities: Flexible Cellular Manufacturing Injection Molding (integrated with assembly cell) State of the Art Injected Foam Molding of Knobs Electronics Design and Development Lever Machining, Gun-Drilling Robotic Welding Coining, Broaching, Drilling

    Floor ATX

    Floor MTX

    Transfer Case

    Column IP Mounted

    Manufacturing Capabilities Technology Review

  • 10

    Fremont, MI Shifter Facility

    QS9000 Certified ISO14001 Certified TS16949 Certified YTD PPM - 12 Delivery - 98

    Plant Size - 156,903 Sq. Ft. Union - UAW Operation - 2 Shifts, 5 Days Avg. Length of Service - 5 Yrs Plant Age - 25 Years Hourly Employees - 370 Salaried Employees - 104

    S H I F T E R P R O F I L ES H I F T E R P R O F I L E

  • 11

    Fremont Manufacturing Technologies

    Processes: Coining Broaching Robotic Welding Drilling Injection Molding Cellular Assembly Knob Manufacturing

    S H I F T E R P R O F I L ES H I F T E R P R O F I L E

  • 12

    Plant Size - 66,000 Sq. Ft. Union - CAW Operation - 2 Shifts, 5 Days Avg. Length of Service - 8 Yrs Plant Age - 45 Years Hourly Employees - 112 Salaried Employees 27 QS9000 Certified ISO14001 Certified Ford Q1 Chrysler Gold Award YTD PPM - 17 Delivery - 92

    Brantford Manufacturing Technologies S H I F T E R P R O F I L ES H I F T E R P R O F I L E

  • 13

    DURA Ganxiang Manufacturing Technologies

    Plant Size - 17,784000 Sq. Meter. Operation - 2 Shifts, 5 Days Plant Age - 47 Years Salaried Employees 294 QS9000 Certified ISO9002 Certified VDA 6.1 Certified ISO/TS16949 Certified Shanghai GM GP10 Certified

    S H I F T E R P R O F I L ES H I F T E R P R O F I L E

  • 14

    Ford Business (N.A.)

    VEHICLE NAME PROGRAM CODE MY PRODUCT (ATX/MTX/COLUMN) FLOOR / IP

    TYPE (STRAIGHT GATE / SERPENTINE/ SBW

    / TIPTRONIC)

    ANNUAL VOLUMES

    CROWN VICTORIA / GRAND MARQUIS / TOWN CAR

    EN114 / FN45 CURRENT COLUMN SHIFTER N/A N/A 200,000

    MARAUDER / FEATURE CAR EN114 CURRENT ATX SHIFTER FLOOR STRAIGHT GATE 15,000CROWN VICTORIA / GRAND MARQUIS / TOWN CAR

    EN114 2005 COLUMN SHIFTER N/A N/A 200,000

    ECONOLINE VN127 CURRENT COLUMN SHIFTER N/A N/A 200,000ECONOLINE VN127 2005 COLUMN SHIFTER N/A N/A 200,000EXPEDITION U222 CURRENT COLUMN SHIFTER N/A N/A 200,000NAVIGATOR U228 CURRENT ATX SHIFTER FLOOR STRAIGHT GATE 40,000EXPEDITION / NAVIGATOR U222/228/354 2007 ATX SHIFTER FLOOR STRAIGHT GATE 200,000EXPEDITION U222 2007 COLUMN SHIFTER N/A N/A 30,000EXPLORER U152 CURRENT COLUMN SHIFTER N/A N/A 400,000FOCUS C307 2008 ATX SHIFTER FLOOR STRAIGHT GATE 220,000FORD CROSSOVER U387/388 2007 ATX SHIFTER FLOOR STRAIGHT GATE 213,000FREESTAR V229 CURRENT COLUMN SHIFTER N/A N/A 90,000FREESTYLE / 500 / MONTEGO D219/258/333 2008 ATX SHIFTER FLOOR STRAIGHT GATE 270,000F-150 P221 CURRENT ATX SHIFTER FLOOR STRAIGHT GATE 175,000F-150 / F-SERIES / EXPEDITION P221/356/U222 2007 COLUMN SHIFTER N/A N/A 800,000F-SERIES SUPER DUTY PN 131 CURRENT COLUMN SHIFTER N/A N/A 350,000FUTURA CD338/378 2006 ATX SHIFTER FLOOR STRAIGHT GATE 280,000MUSTANG SN95 CURRENT ATX SHIFTER FLOOR STRAIGHT GATE 100,000MUSTANG SN95 CURRENT MTX SHIFTER N/A N/A 60,000MUSTANG S197 2006 ATX SHIFTER FLOOR STRAIGHT GATE 115,000MUSTANG S197 2007 MTX SHIFTER N/A N/A 60,000RANGER UPN105 CURRENT COLUMN SHIFTER N/A N/A 150,000

  • 15

    Chrysler Business (N.A.)

    VEHICLE NAME PROGRAM CODE MYPRODUCT

    (ATX/MTX/COLUMN) FLOOR / IP

    TYPE (STRAIGHT GATE / SERPENTINE/ SBW

    / TIPTRONIC)

    ANNUAL VOLUMES

    Police Car LX2006

    ATX - Column w/ autostick

    10,000

    MINIVAN (ULTIMATE FAMILY VEHICLE) RT2007.5 ATX I/P Serpentine w/A'Stick

    430,000

    LIBERTY KJ 2002-07.5 ATX Floor Straight Gate 170,000Dodge MidSize SUV KA 2007.5 ATX Floor Straight Gate 60,000LIBERTY REPLACEMENT KK 2007.5 ATX Floor Straight Gate 170,000Wrangler & Scrambler JK 2007 ATX Floor Straight Gate 55,000Wrangler & Scrambler JK 2007 Trans Case w/Cable Floor Serpentine 90,000DAKOTA ND 2005 MTX / Column N/A N/A 150,000DURANGO HB 2004 ATX - Column N/A N/A 145,000Ram LD & HD DR 2002 ATX - Column N/A N/A 475,000Ram LD - Floor Lever DR 2006 MTX N/A N/A 15,000Ram HD - Floor Lever DR 2005 MTX N/A N/A 55,000

  • 16

    GM Business (N.A.)

    PRODUCT CAR LINE GM CODE MY PRODUCT (ATX/MTX/COLUMN)

    FLOOR / IP

    TYPE (STRAIGHT GATE / SERPENTINE/ SBW

    / TIPTRONIC)

    VOLUMES

    Saturn LS CURRENT ATX SHIFTER FLOOR STRAIGHT GATE 50,000Impala / Monte Carlo GMX 210/230 CURRENT ATX SHIFTER FLOOR STRAIGHT GATE 150,000Grand Prix GMX 367 CURRENT ATX SHIFTER FLOOR STRAIGHT GATE 150,000Buick LaCrosse GMX 365 2005 ATX SHIFTER FLOOR STRAIGHT GATE 125,000

  • 17

    Other Business (N.A.)

    VEHICLE NAME PROGRAM CODE MY PRODUCT (ATX/MTX/COLUMN) FLOOR / IP

    TYPE (STRAIGHT GATE / SERPENTINE/ SBW

    / TIPTRONIC)

    ANNUAL VOLUMES

    HONDA ODYSSEY BL CURRENT COLUMN N/A N/A 120,000HONDA PILOT HP CURRENT COLUMN N/A N/A 80,000TOYOTA TUNDRA CURRENT COLUMN N/A N/ATOYOTA SEQUOIA CURRENT COLUMN N/A N/A

  • 18

    New ATX Shifter TechnologyModular Shifter

    Core Shift Function Contained within a Reusable Module Adaptable with Minimal Tool Change-Over for

    Straight and Cross-Over Gate PatternsCable and Rod LinkagesDifferent Gearbox Models

    Accepts all Knob StylesFront, Side and Top Button

    Electronic Brake and Key Interlock

    Benefits Reduced Product Development Cost and Timing

    Reduced Cost - $5 Save over Traditional Designs

    Simplified Brake and Key Interlock System

    Quiet Brake Interlock System

    Reduce Side-to-Side Lash

    Technology Review

    BTSI Noise

    0

    8.46.47.2

    02468

    101214161820

    Dura Module 03 Altima 03 Camry 04 LexusRX330

    Sones(Loudness)

    Product Development Time (months)

    0 5 10 15 20

    Dura Module

    All New Program

  • 19

    Technology ReviewModular Shifter Benchmarking

  • 20

    Modular Shifter Benchmarking Technology Review

  • 21

    New TechnologyDigiShiftTM Hybrid Shift By Wire System

    Compact Shift Lever (1/8th the volume of traditional designs)Gearbox Actuator

    Direct Input Shaft AttachmentDC Motor DrivenPlanetary Gear Set Locking Solenoid for back-up operation (no battery)

    ECU16 bit Primary MicrocontrollerSecondary Watchdog controllerFull CAN Controller

    Benefits:Available for Current Transmission technology

    Full Production Implementation - January 2006

    Manual Back-up Solution available

    Styling & Packaging Flexibility

    Ease Of Assembly

    Consistent Shift Effort & Performance Feel

    Improved Safety and Fuel Economy

    Reduced NVH

    P R N 3 2D 1

    Forc

    e

    DigiShiftTM System

    Current DigiShiftTM

    1/8 the required volume!

    Technology Review