BOSAL BUSY/BINA Bosal International NAO April 2020
Bosal Group Ypsilanti Plant Tech Center BOSAL is a global tier-1 supplier to all major automotive OEMs and with long standing customer relations Strictly confidential Founded Family 1923 in the owned Netherlands Mission BOSAL is committed to delivering Long Industry- the best possible value for clients € 600M standing leader in through innovative and high quality customer engineering revenue capabilities relations solutions for mobility 2.200 Global employees footprint worldwide 2
Bosal Group Ypsilanti Plant Tech Center BOSAL offers a full range of innovative solutions to industry leaders worldwide Fuel Cold Hot end EGHRS Pre- Evaporator reformer end heater Vehicle parts Strictly confidential Air Seat Jacks Towbars vessels frames Emission Control Energy Conversion Systems Systems 3
Bosal Group Ypsilanti Plant Tech Center BOSAL’s global footprint, production and R&D facilities 1 2 3 4 C 5 Mexico, Querétaro, ECS Mexico, Ramos, ECS Russia, Nizhny Novgorod, ECS Czech Rep., Brandýs, ECS USA, Ypsilanti, ECS Year: 1999 FTE: 730 Year: 1994 FTE: 375 Year: 2015 FTE: n.a. Year: 2011 FTE: 75 Year: 1999 FTE: 141 Area: 20,000m 2 Area: 10,000m 2 Area: 2,180m 2 Area: 4,600m 2 Area: 16,700m 2 Strictly confidential 6 10 B 4 Spain, Zaragoza, ECS 5 C 13 A Year: 1991 FTE: 149 1 11 Area: 8,000m 2 6 7 12 3 A 13 7 2 BOSAL plant BOSAL R&D center 9 E 8 D BOSAL office Belgium, Lummen, ECS Turkey, Gebze, ECS (AM), Year: 1988 FTE: 148 Towbar, air vessels and other Area: 11,600m 2 Strategic partner Year: 2010 FTE: 282 Area: 18,220m 2 12 11 B 10 E 9 D 8 Czech Rep., Čelákovice, AM Netherlands, Vianen, ECI Brazil, Itupeva, ECS, Jacks South Africa, Pretoria, ECS (AM), Ukraine, Zaporozhye, AM Year: 2019 FTE: 20 Year: 2005 FTE: 127 Year: 1979 FTE: 40 Year: 2008 FTE: 57 towbar design, development & Area: 2,000 m 2 Area: 11,000 2 Area: 14,000 m 2 Area: 17,000m 2 testing Year: 1955 FTE: 154 Area: 47,085m 2 4
Bosal Group Ypsilanti Plant Tech Center Bosal Ypsilanti Plant & North America Tech Center Strictly confidential 5
Bosal Group Tech Center Ypsilanti Plant Bosal Ypsilanti customers Major programs Customer Since 1) BUSY Customer relationship Manufacturing footprint Bosal Customer in the US and Mexico for cold end, hot > Chevy Cruze end and EGR applications Strictly confidential 1990 for many years. Last GM > Cadillac CT6 program (CT6) stopped Jan 2020 Customer in the US (BUSY) > Jeep Wrangler for cold end applications 2003 for many years. Contract for Jeep Wrangler EOP in April 2018 1) Bosal has established long-term relations with GM and Chrysler (FCA) in Europe and North America Strictly private & confidential 6
Bosal Group Tech Center Ypsilanti Plant Bosal Ypsilanti: key production figures • Plant size: 16,700m² / 180,000ft 2 • FTE : ~180 in 2018 (30 in 2020) • Annual volume 2018 : 400K Strictly confidential • On time delivery rate : 100 % • Scrap rate : 0.8 % Ypsilanti • Recordables YTD Aug 2018 : 6 US • LTAR Accidents in 2018 : 2 During 2020 the plant has been ramped down to an organization of 25, managing OES projects and preparing for new program start-ups in July 2020 and April 2021 Strictly private & confidential 7
Bosal Group Tech Center Ypsilanti Plant Bosal on site manufacturing capabilities CNC bender and product sample in control fixture Strictly confidential Automated boxline and sample muffles Welding robot and sample part in control fixture 8
Bosal Group Tech Center Ypsilanti Plant Bending capacity available: 2.5 million bends a year in 2 shifts • 1 double stack CNC DB 76 bender • 3 multi stack CNC benders Strictly confidential • 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 Strictly private & confidential 9
Bosal Group Tech Center Ypsilanti Plant Boxmaking capacity available: 350.000 boxes a year in 2 shifts • 1 fully automated boxline: ridgelocking, flaring, interior stuffing & end • Strictly confidential cap spinning • Cross sections available: expandable with off site Bosal cross sections Strictly private & confidential 10
Bosal Group Tech Center Ypsilanti Plant 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 Strictly confidential Atos & Faro measuring capabilities • Strictly private & confidential 11
Bosal Group Tech Center Ypsilanti Plant Material flow flat storage on wheels line feeding, flow racks Strictly confidential waterspider feeds line line feeding, tugger 12
Bosal Group Tech Center Ypsilanti Plant Manufacturing Excellence and Certifications ISO 14001 ISO IATF/TS GM BIQS certified recertified 2018 recertified 2019 2018 Strictly confidential Strictly private & confidential 13
Bosal Ypsilanti Floor Space Acoustic Testing Bending Proto Shop Strictly confidential Ware- house Space Mat. available Ware- house Strictly private & confidential 14
Bosal Group Tech Center Ypsilanti Plant Team Plant Director Ypsilanti NAO Control Strictly confidential & IT Production & Supply Program Mgmt. & Development, HR & HSE Sourcing Quality Manufacturing Chain Continuous testing & engineering Improvement prototyping • Qual engineer: • Forklift • Manufact. Engineer measuring, cut & • Dev. engineers. driver • Maintenance etch Engineer • Weld and bend tech • Cat designer • 3 Operators • Testing engineer • 3 Welders • Protoshop lead • welder 15
Bosal Group Tech Center Ypsilanti Plant Flexing up competences 64 people available on call back list Balanced training matrix. Call back list covers: 8+ years of experience: - Operators for bending, weld robots, boxmaking - Operators - Welders for manual weld processes - Welders - Forklift drivers - Forklift drivers - Technicians for bending, welding, boxmaking Strictly confidential - Technicians - Maintenance, mechanical and electrical - Maintenance 16
Bosal Group Ypsilanti Plant Tech Center Bosal Product & Process Dev. Capabilities Strictly confidential 17
Bosal Group Ypsilanti Plant Tech Center Bosal Virtual Dev. Capabilities Strictly confidential 18
Bosal Group Tech Center Ypsilanti Plant Bosal Group Support for Ypsilanti plant Program Management organization backed up with global PCP-PLM • system Sourcing support structure with Program, Commodity and series Buyers • Strictly confidential • 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 19
Bosal Group Ypsilanti Plant Tech Center Bosal Testing Capabilities • Clayton chassis dynamometer & anechoic chamber • Fatigue Test rigs Strictly confidential • Hot and cold flow bench • Kilns • Burst test rig • Leak test rig • Transmission loss bench 20
Bosal Group Ypsilanti Plant Tech Center Engineering & Protoshop Capabilities • Welding • Weld cut and etch lab • Fixture building Strictly confidential • 3D scan – ATOS • CNC mill • Hydraulic press 21
Strictly confidential THANKS 22
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