The Benefit of Simultaneous Engineering

1. The Benefit of Simultaneous Engineering • At least 95% of the Total Life Cycle Cost are determined during the Concept & Design phase of a project, therefore the more experienced people you have involved at that phase, the more opportunity you have to reduce your Total Life Cycle Cost.

2. Role of a Simultaneous Engineering Partner • Introduce Customers To The Various Technologies And Layouts Used Today In The U.S. And The Rest Of The World. • Become The Main Contact For The Machine Tool Builders Regarding Coolant And Chip Handling • Present And Evaluate The Various Alternatives Available To The Customer • Develop A Plant Wide Plan For Coolant Filtration and Chip Handling • Develop Specifications/Specification Adherence

3. The Simultaneous Engineering Process • Define program objectives • Identifying and defining strategies and equipment to meet the program objectives • Evaluate the strategies and equipment identified • Specifications

4. Examples of Coolant Filtration Objectives • Reliability and maintainability • Flexibility • Simplicity/User Friendly • Performance • Reducing disposable media consumption • Value engineering

5. Prioritizing Objectives • Once objectives are identified they must be prioritized. • Some objectives may be mutually exclusive.

6. Identifying and Defining Strategies and Equipment • The S.E. partner will collect the pertinent information from the appropriate machine tool vendors in order to size the equipment • The customer and the S.E. partner will list various methods available to meet the program’s objectives • The customer and the S.E. partner will decide which alternatives merit further definition • The S.E. partner will then prepare flow schematics and proposal drawings of the various strategies defined

7. Evaluation of the Alternatives • T-charts listing advantages and disadvantages of the options • Budget Pricing • Life Cycle Cost Analysis • Benchmarking/Plant Visits • Reliability and Maintainability • FMEA

8. Results of the Process • Equipment specifications for the strategy selected

9. Deliverables • Machine Tool Coolant Requirement Data Sheets • Detailed Coolant System Requirements • Evalutions: drawings, budgets, LCC, FMEA, R&M, and T-charts • Equipment Specifications

10. Why is Zealtek your best choice as a S. E. Partner • Objectivity • Resources • Experience • Creativity / Diverse Product Knowledge • Performance • Price Competitiveness

11. Objectivity • Zealtek is not constrained to one or two methods for coolant filtration or chip handling.

12. American Axle & Mfg. GMT 800 DaimlerChrysler Indiana Transmission Plant 45RFE Ford Livonia AX4N Ford Van Dyke FN Program Ford Windsor (TMEP) Ford Romeo Aluminum Block Expansion Program Ford Lima Engine Plant Ford Windsor 3 Valve Head Lines Ford Essex Engine Plant Ford Cleveland New V6 Ford Lima New V6 GM Livonia PV6 GM Romulus V8 GM Windsor 4T-60E GEMA Dundee, MI Navistar Huntsville, AL Navistar Indianapolis, IN Austin-Rover, U.K. Various other projects Program Experience

13. Simultaneous Engineering Experience • DCX KEP 2.7L and 3.5L • DCX ITP • Ford Romeo • Ford Windsor • GM 9002 • American Axle and Manufacturing • Eaton Mexico • GEMA Dundee, MI

14. Creativity by Design • Ford Lima and Essex Engine Plants - Completely above floor with individual pump back tanks and individual pressurized return lines • DaimlerChrysler ITP - Completely above floor with individual pump back tanks and a common return header • Heller/American Axle Three Rivers, MI - Completely above floor using a centralized pump back conveyor with floor mounted filter • Ford Windsor - Above floor conveyors to in-floor pump back tanks to floor mounted filters • Ford Romeo Engine Plant - Trench to large lift stations with floor mounted filters • Navistar, GM Romulus, and GM Livonia - Trench to pit mounted filtration systems.