General Sales Presentation 2014 • Overview of Montupet • Technical expertise • Focus on chassis parts • Project management M O N T U P E T
Strategy • Maintain and confirm technological leadership as a supplier of reference to carmakers • Provide simultaneous engineering services adapted to each customer • Ensure a global footprint • Widen the customer base • Build on a sound financial base … guided by strong company values
Our products Design and production of complex cast aluminium components for the automotive industry Expertise Expertise 80% Cylinder heads 50+ references 20% Other parts Master cylinders, suspension parts, turbo housings…
History 1894 Mr. Pierre Montupet opens a foundry in Nogent, France 1966 Initial public offering (Paris stock exchange) 1981 Automotive crisis . Pechiney becomes the only industrial shareholder 1986 Management buy-out . Focus on automotive industry 1987-89 Purchase of foundries in Spain and UK 2000-06 Building of plants in Mexico and Bulgaria 2010 Focus on core business : engine and suspension parts 2013 Development in Asia. Joint venture with Jaya Hind in India Today 420 M€ turnover and a global footprint
Diversified customer base 5 - 10 million cars sold in 2013 M ONTUPET CUSTOMERS Up to 5 million cars sold in 2013 M ONTUPET CUSTOMERS
Revenue split *VW Group includes Volkswagen, Audi, Bentley, Porsche, Skoda
Montupet worldwide Production site Sales office Sweden UK (Belfast) Germany France (HQ + 2 sites) Bulgaria (Ruse) USA Spain (2 sites) Mexico (Torreon) India China (Dewas) 3000+ employees
Montupet worldwide / France Laigneville Since 2000 Cylinder heads development Paris Headquarters EMPLOYEES 550 PRODUCTS Cylinder heads CAPACITY* 1 000 000 CH / year CLIENTS Renault / Ford / Volvo Spain, Turkey, Thailand / Argentina, SHIPPING South Africa, UK / Sweden, Belgium Chateauroux Since 1970 Suspension parts development EMPLOYEES 350 PRODUCTS Cylinder heads, suspension parts CAPACITY* 800 000 CH / year CLIENTS Renault / Audi-Bentley / PSA Turkey-Russia-Spain/ Germany-UK- SHIPPING China/ France *Capacity in cylinder head (CH) equivalent
Montupet worldwide / Europe Ruse (Bulgaria) Since 2010 EMPLOYEES 700 PRODUCTS Cylinder heads, structural parts Belfast (UK) Since 1989 CAPACITY* 2 500 000 CH / year CLIENTS Renault/ Audi / BMW / Ford / PSA EMPLOYEES 550 Turkey / Germany, Slovakia / SHIPPING PRODUCTS Cylinder heads Romania, Germany, Poland / UK CAPACITY* 1 400 000 CH / year CLIENTS Ford / PSA Turkey, Thailand, Argentina, South SHIPPING Africa, China, Germany / France Zaragoza (Spain) Since 1987 Master cylinders and misc. parts dev. EMPLOYEES 500 PRODUCTS Turbo housings, braking parts CAPACITY* 800 000 CH / year Vitoria (Spain) Since CLIENTS Honeywell / Continental / John Deere 1988 Tooling subsidiary SHIPPING France EMPLOYEES 120 PRODUCTS Molds, coreboxes *Capacity in cylinder head (CH) equivalent
Montupet worldwide / Overseas Torreon (Mexico) Since 1999 EMPLOYEES 600 PRODUCTS Cylinder heads, braking parts CAPACITY* 2 800 000 CH / year CLIENTS Ford / GM / Continental Teves / Bosch SHIPPING USA / South Korea / China, Mexico Dewas (India) SOP 2016 Jaya Hind - Montupet JV EMPLOYEES 240 PRODUCTS Cylinder heads CAPACITY* 500 000 CH / year CLIENTS Ford / Mahindra SHIPPING India *Capacity in cylinder head (CH) equivalent
• Technical challenges TECHNICAL • Engine downsizing EXPERTISE • Metallurgy • Dimensional accuracy • Complex coring • R&D • Quality performance
Technical challenges Expertise Expertise Global automotive Engine downsizing industry trend Complex cooling Customer High mechanical Low CO 2 system and requirements properties emissions integrated functions Montupet Mastery of Dimensional Complex coring expertise metallurgy accuracy design -Cost and weight optimisation R&D -Long term quality performance
Engine downsizing, a global trend Expertise Expertise 150 kW/l 125 kW/l More efficient, 100 kW/l smaller engines* 75 kW/l 50 kW/l Gasoline 25 kW/l Diesel 0 kW/l 1990 1995 2000 2005 2010 2015 * Data are extracted from Montupet equipped engines (PSA, BMW, Ford, Renault, GM)
Metallurgy: alloy & heat treatment (HT) Expertise Expertise Large range of alloys and HT HT validation ▼ HT simulation ALLOY HT Part example T7 Water quench Ford (DV6)… AlSi7Mg (A356) ( Primary ) T7 Air Quench GM (Z-22)… T7 Water quench M&M (2.2L CRDI 4 cyl.)… AlSi7MgCu0,5 ( Primary ) T7 Air Quench Ford (FOX I3 GTDI)… AlSi10Mg T7 Water quench Ford (Puma I4)… ( Primary ) AlSi10MgCu0,5 T7 Water quench Audi (W19,W36,W37)… ( Primary ) KF (No HT) Renault (D4, K4, K7)… T5 Ford (FOX GDI), Renault (K9, M9)… AlSi7Cu3 (319) ( Secondary ) T7 Water quench Ford (I4 PFI, I4 GDI)… T7 Air quench Cylinder head in development ▲ Strain gauges for testing after HT Control of the mechanical properties during the whole product lifecycle
Dimensional accuracy Expertise Expertise � Complex geometry design Optimise weight and geometry � Tests and process control for low CO 2 emissions ▲ CAD model VS real part ▲ 3D model ▲ X Ray Tomography (CT Scan) ▲ Non destructive thickness analysis ▲ Sections for soundness investigation ▲ GOM: geometrical dimensioning
Complex coring Expertise Expertise Customer design and innovation Producing cores of advanced complexity Integrated Double water Ultra thin cores functions jacket ▲ Integrated exhaust manifold ▲ Audi W36/37 ▲ Audi V6 3l 250hp Ø < 3 mm
Research & development Expertise Expertise Comprehensive simulation competences Scientists 1 4 0 & engineers Improve products and processes ▲ Static gravity filling • Develop new alloys and heat treatments ▲ Tilted gravity filling (Magma) (QuikCast) • Create new industrial solutions ◄ Core shooting (QuikCast) • Technology intelligence • Numerous patents registered ▲ Solidification ▲ Low pressure filling (QuikCast) (Magma)
Quality performance (ppm) Expertise Expertise 10 000 2013 external scrap, all production sites ppm 8 000 Typical foundry industry 6 000 4 000 2 000 0
• Demand for aluminium parts FOCUS ON • A global Montupet business CHASSIS PARTS • Technical development
Demand for aluminium parts Carmakers Montupet Vehicle weight reduction Aluminium foundry expert Mass production of high quality lightweight die cast aluminium chassis parts Rear knuckle Cross member Machined rear knuckle Front upright
A global Montupet business • Development center for chassis parts: Chateauroux (France) • Comprehensive range of casting processes: • Static gravity • Tilted gravity France (Chateauroux) • Low pressure Bulgaria (Ruse) Mexico (Torreon) 60 000 Weekly capacity (parts) 50 000 Mexico 40 000 Bulgaria 30 000 20 000 France 10 000 0 2004 2006 2008 2010 2012 2014 2016 2018 2020
Technical development • Simultaneous engineering and best-in-class team of metallurgists • Component geometry • Mechanical properties • Tooling • Expertise in finite element and casting simulation • Foundry simulation: Magmasoft, Simulor • FE calculation: Nastran, Ideas • Specific controls for safety parts • X-ray with automatic sanction • Fluorescent liquid penetrant inspection • Chemical and metallurgical analyses • Dimensional control
• Typical project team PROJECT • General management MANAGEMENT • MMS (Montupet Management System)
Typical project team Project quality Board Key account manager Plant steering Supporting team committee Quality Product leader Dedicated project team design engineer Design office Project Pre-launch Casting Coring projects engineer manager engineer Plant Development Machining engineering center Plant engineer engineer Product / process engineering R&D
General management S. Magnan* Chairman & CEO D. Crozet* M. Majus* P. Mauduit* D. Massinon Managing CFO HR director R&D director director S. Gauthier P. Bertrand P. Dupont V. Russ Manufacturing Engineering Purchasing Sales & marketing director director director director Key account Plant directors managers *Major shareholders of Montupet
General performance toolbox Standard tools for all Manufacturing Montupet plants and general performance Visual management Preventive maintenance Root cause analysis Customer focus Value stream mapping Top class team Human Training and appraisal Development FMEA resources Kanban 5S …
Conclusion MONTUPET Specialist in high added-value cast aluminium Specialist in high added-value cast aluminium components for the automotive industry components for the automotive industry A technological leader with 7 production sites A technological leader with 7 production sites and a global footprint and a global footprint Preferred supplier status at the world’s Preferred supplier status at the world’s global carmakers and tier 1 OEMs global carmakers and tier 1 OEMs
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