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Pyeongtaek Plant Sep 24, 2009

Pyeongtaek Plant Sep 24, 2009. Business Review. Headcount. As of Sep 23, 2009. Org Chart. Sales. By Products (Jan to Aug, 2009). Estimated. Million Won. Sales. By Customers (Jan to Aug, 2009). Million Won. Quality. Tau Cover Ass’y VI5.0 Machining Failure. R-Eng’s Rotor’s

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Pyeongtaek Plant Sep 24, 2009

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  1. Pyeongtaek PlantSep 24, 2009

  2. Business Review

  3. Headcount As of Sep 23, 2009

  4. Org Chart

  5. Sales By Products (Jan to Aug, 2009) Estimated Million Won

  6. Sales By Customers (Jan to Aug, 2009) Million Won

  7. Quality Tau Cover Ass’y VI5.0 Machining Failure R-Eng’s Rotor’s Thickness Problem By PMG PPM PPM Customer PPM Supplier PPM

  8. R-Engine Turbo Charger Field Claim Status of customer claim • R-BSM Bore diameter Spec. over  Insufficient oil supply to turbo charger Cause • S/W Machine machining precision issues • Auto bore gage clamping issues • No filtering function at EOL tester Upper HSG Lower HSG Corrective action • Chips removal by Air  Oil • Auto bore gage clamping repaired

  9. Tau FEMA Quality Issues Status of customer claim • Machining Failure & parts returned Cause • On machining, there was no checking of detected area • There was no dimensional mark on Assembly drawing, • so there was no recognition of importance of area. Corrective action 3mm • Drawing Changed ( On customer Assembly drawing, added it’s dimension. • Updated dimensional checking standard. (MKL) • Monitoring Result :During 3 month, there was no same claim from customer. 8

  10. R-engine IP Quality Issues Status of customer claim • Rubber De-bonding from IP hub IP Rubber Cause • Missing operation • No fool proof IP Hub Corrective action Separated point • Fool proof after push-out test MKL’s difficulties • Re-occurring various initial quality problems • MKL Org has to support MIS

  11. Inventory Turns Target KRW:Million

  12. Air-freight cost for R-Engine Reason 1. unexpected increasing demands and very changeable customer forecast

  13. Air-freight cost for R-Engine Reason 2. too long lead-times of supply chain 1. Accelerating localization 2. Need more safety stock minimum 4 weeks.

  14. Safety Safety recordable incident rate chart • Date of last lost time incident occurred are 1552as of the end of Aug, 2009. • Days without recordable incident are 353 as of the end of Aug, 2009.

  15. Sales/EBIT Trend Mar to Aug

  16. Plant Issues

  17. 1. Potential issues by Sales volume increasing A. Long Term Sales Forecast [Unit: pcs] * Volume forecast will be revised in the early of October. 16

  18. B. Expected Issues • Plant capacity • Plant space • Power • Compressor • Headcount • Supplier capacities • Localization (Gears & Gerotors) • Inventory

  19. 2. Cost Issues by import parts A. EBITDA Trend

  20. B. Localization Plan • Proto Sample Evaluation Sep 30, 2009 • Tooling & Line Set-Up Nov 15, 2009 • PPAP Submission to MKL Dec 15, 2009 • PPAP Submission to HMC Dec 31, 2009 • HMC Evaluation Mar 31, 2010

  21. C. Cost Saving 16,868 Won 14.8%↓ 9,224 Won 7.5%↓ Won Won Theta BSM R- BSM 300,000 Modules  2,768 million Won Saving 150,000 Modules  2,530 million Won Saving

  22. D. Detail List

  23. A. Theta GDI Open Issues 3. R & D Issues • Production design - There has been design changes for each customer event. - BSM design for PP stage has been finalized. - Spring and housing 3 designs may be changed near soon. - 2D component drawings should be completed by Sep 23rd(KST) as they are. • EOL spec for GDI module - ESP limit is required for the production and EOL correlation. - MKL needs to have EOL spec even though the interim limits for the customer audit scheduled on Sep 24th. • DVP&R - MD to perform the DVP&R for PP design. - Plymouth is processing high speed and sweep test currently. • ◆ Cavitation issue • - Severe cavitation mark found for GDI P2 module tested 320hr high speed in HMC. Actually rated speed • increased from 6000erpm to 6300erpm and oil pump performance was changed from current MPI version. • - Plymouth is investigating the BSM in detail.

  24. B. R-BSM Open Issues • Oil pump noise issue - Current production module shows the border line for oil pump noise. - HMC and MKL is trying to improve the NVH through the axial clearance. This may help MD to eliminate induction hardening for driven shaft. • M6 bolt issue - MKL had M6 bolt assembly trouble with the breakage and the elongation at the bolt thread recently. - Plymouth will do the bolt clamping capability review with the housings and bolts provided by MKL. And also MKL is doing the trial with no machined mounting surface of housing 1 in order to increase the friction co-efficiency. • Oil strainer material change - The change of oil strainer material was suggested due to cost reduction. - HMC completed engine feasibility test for the changed material and asked to submit CFR print by Sep 25th.

  25. 4. Commercial Issues A. Commitment to Customer • R&D Localization progress • R IP Localization B. Piece price and tooling cost negotiation • Tau 5.0L VI FEMA • Theta2 GDI BSM • R ENG Crankshaft Gear Localization • ◈ All will be done by Oct 23th C. No next items for the future

  26. 5. Maintenance & Technical Issues • Maintenance & Technical main issues - Lack of spare parts. - SW M/C#1 runs at one spindle side. - SW M/C#2 runs at “A” fixture because of Brake damage of “B” axis. - Washer will be rebuilt to increase pump pressure and to add nozzles. - If we set up the SW M/C#3, we should make a M8,M6 bolt disassembly M/C. • Maintenance Plan - After inventory secure, team will align SW M/C#1 again. - Ordered the new brake and the replacement will be done by the end of October. - Rebuilding a Washer will be done by the middle of October. - New Washer in order to remove the chips being stayed on the BSM will be installed by middle of October. - M8 process bolt torque M/C will be done by end of November. - Turbo flow test M/C will be installed by end of October.

  27. 6. HR & Organization A. Hiring salaried position Headcount trend Headcount by Year 86 85 60 59 55 Headcount By Dept Sales per employee

  28. New position to be hired • M.E Engineer  Replacement of SG Lee • Quality Engineer  Strengthen Quality Dept • Materials & Logistics assistant  Change from Hourly to Salaried • Financial Assistant  Replacement of JS Kim B. Need Key Person Retaining program Now After Oct HC 60% 70%

  29. New position to be hired • M.E Engineer  Replacement of SG Lee • Quality Engineer  Strengthen Quality Dept • Materials & Logistics assistant  Change from Hourly to Salaried • Financial Assistant  Replacement of JS Kim B. Need Key Person Retaining program HC 60%

  30. 감사합니다.

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