April 2020 Bosal Group Ypsilanti Plant Tech Center BOSAL is a - - PowerPoint PPT Presentation

BOSAL BUSY/BINA

Bosal International NAO

April 2020

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BOSAL is a global tier-1 supplier to all major automotive OEMs and with long standing customer relations

Family

• wned

Founded 1923 in the Netherlands

€ 600M revenue Long standing customer relations

Industry- leader in engineering capabilities

Global footprint

2.200 employees worldwide

Mission BOSAL is committed to delivering the best possible value for clients through innovative and high quality solutions for mobility

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BOSAL offers a full range of innovative solutions to industry leaders worldwide

Towbars Air vessels Jacks

Emission Control Systems Vehicle parts Energy Conversion Systems

Pre- heater Fuel reformer Evaporator Seat frames Cold end Hot end EGHRS

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BOSAL’s global footprint, production and R&D facilities

Area: 20,000m2 FTE: 730 Year: 1999 Czech Rep., Brandýs, ECS Area: 10,000m2 FTE: 375 Year: 1994 Mexico, Querétaro, ECS Area: 2,180m2 FTE: n.a. Year: 2015 Mexico, Ramos, ECS Area: 4,600m2 FTE: 75 Year: 2011 Russia, Nizhny Novgorod, ECS Area: 18,220m2 FTE: 282 Year: 2010 Turkey, Gebze, ECS (AM), Towbar, air vessels and other Area: 8,000m2 FTE: 149 Year: 1991 Spain, Zaragoza, ECS Area: 11,0002 FTE: 127 Year: 2005 Ukraine, Zaporozhye, AM

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Area: 2,000 m2 FTE: 20 Year: 2019 Czech Rep., Čelákovice, AM Area: 11,600m2 FTE: 148 Year: 1988 Belgium, Lummen, ECS

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BOSAL plant BOSAL R&D center Strategic partner

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BOSAL office

Netherlands, Vianen, ECI Year: 1979 FTE: 40 Area: 14,000 m2 Area: 16,700m2 FTE: 141 Year: 1999 USA, Ypsilanti, ECS Area: 47,085m2 FTE: 154 Year: 1955 South Africa, Pretoria, ECS (AM), towbar design, development & testing Area: 17,000m2 FTE: 57 Year: 2008 Brazil, Itupeva, ECS, Jacks

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Bosal Ypsilanti Plant & North America Tech Center

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Since1) 1990 2003 Major programs BUSY > Chevy Cruze > Cadillac CT6

1) Bosal has established long-term relations with GM and Chrysler (FCA) in Europe and North America

Customer

Bosal Ypsilanti customers

Customer relationship Customer in the US and Mexico for cold end, hot end and EGR applications for many years. Last GM program (CT6) stopped Jan 2020 Customer in the US (BUSY) for cold end applications for many years. Contract for Jeep Wrangler EOP in April 2018 Manufacturing footprint Bosal > Jeep Wrangler

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Ypsilanti

US

Bosal Ypsilanti: key production figures

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• Plant size:

16,700m² / 180,000ft2

• FTE

: ~180 in 2018 (30 in 2020)

• Annual volume 2018

: 400K

• On time delivery rate

: 100 %

• Scrap rate

: 0.8 %

• Recordables YTD Aug 2018

: 6

• LTAR Accidents in 2018

: 2 During 2020 the plant has been ramped down to an organization

• f 25, managing OES projects and preparing for new program

start-ups in July 2020 and April 2021

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Bosal on site manufacturing capabilities

CNC bender and product sample in control fixture Automated boxline and sample muffles Welding robot and sample part in control fixture

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Bending capacity available: 2.5 million bends a year in 2 shifts

• 1 double stack CNC DB 76 bender
• 3 multi stack CNC benders
• Tool range from 50.8mm up to 101.6 mm tube

OD

• All cutting and sizing capabilities to match the

bending diameters

• 2 hydraulic presses
• CNC machining cell
• Ram forming capabilities

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Boxmaking capacity available: 350.000 boxes a year in 2 shifts

• 1 fully automated boxline:
• ridgelocking, flaring, interior stuffing & end

cap spinning

• Cross sections available:

expandable with off site Bosal cross sections

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Welding capacity available: 20.000 robot weld hours per year in 2 shifts

• Single and double torch welding cells
• 10 to 15 ft welding beam spam
• 3 free manual welding bays
• Cut & etch weld test capabilities
• Atos & Faro measuring capabilities

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flat storage on wheels line feeding, tugger line feeding, flow racks waterspider feeds line

Material flow

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Manufacturing Excellence and Certifications

ISO 14001 recertified 2018 ISO IATF/TS recertified 2019

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GM BIQS certified 2018

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Ware- house Space available Mat. Ware- house Bending Acoustic Testing Proto Shop

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Bosal Ypsilanti Floor Space

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Team

Bosal Group Ypsilanti Plant Tech Center

Plant Director Ypsilanti NAO Control & IT HR & HSE Quality Production & Manufacturing engineering Supply Chain Program Mgmt. & Continuous Improvement Sourcing

• Manufact. Engineer
• Maintenance
• Weld and bend tech
• 3 Operators
• 3 Welders
• Qual engineer:

measuring, cut & etch

• Forklift

driver

Development, testing & prototyping

• Dev. engineers.

Engineer

• Cat designer
• Testing engineer
• Protoshop lead
• welder

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Flexing up competences

Bosal Group Ypsilanti Plant Tech Center

64 people available on call back list 8+ years of experience:

• Operators
• Welders
• Forklift drivers
• Technicians
• Maintenance

Balanced training matrix. Call back list covers:

• Operators for bending, weld robots, boxmaking
• Welders for manual weld processes
• Forklift drivers
• Technicians for bending, welding, boxmaking
• Maintenance, mechanical and electrical

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Bosal Product & Process Dev. Capabilities

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Bosal Virtual Dev. Capabilities

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Bosal Group Support for Ypsilanti plant

Bosal Group Ypsilanti Plant Tech Center

• Program Management organization backed up with global PCP-PLM

system

• Sourcing support structure with Program, Commodity and series Buyers
• Equipment support led by our central Manufacturing Engineering team
• Virtual Manufacturing Process Simulation(s)
• Optionally increase the on site support by moving in bending, welding

and boxmaking engineers from our Mexican facility

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Bosal Testing Capabilities

• Clayton chassis dynamometer

& anechoic chamber

• Fatigue Test rigs
• Hot and cold flow bench
• Kilns
• Burst test rig
• Leak test rig
• Transmission loss bench

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Engineering & Protoshop Capabilities

• Welding
• Weld cut and etch lab
• Fixture building
• 3D scan – ATOS
• CNC mill
• Hydraulic press

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THANKS