Prep for GM- Korea team

1. Prep for GM- Korea team NuinTek – DC Filter Capacitor , Visit GM Confidential

2. Desai Request – Alan Price and GM-K Team for NuinTek visit. Issue : Large Gap between GM ( $ 72 ) and LG E ( $97 ) on price of DC Capacitor asm. Need $25 reduction. Analysis : Even though NuinTek has made significant progress in cost reduction, We support Suresh, in efforts to reduce the gap further. No significant change in SOR specification is anticipated, and NuinTek has agreed to GM specification. Plan : 1. LG E to request cost breakdown of $ 97 from NuinTek and share with GM. ( Sam Cho, Pending) 2. GM' Suresh Palaniswamy to review design, mass and cost breakdown details. ( Sam Cho, Pending ) 3. Visit NuinTek Eng./Mfg. facility, ( 1:30 hrs from Seoul city area ) and follow up on cost reduction effort with LG E engineer/buyer. ( Sam Cho agreed ) Need to select a visit day and GM & LG team members. ( Feb 26th , Tuesday ) 4. Coach GM-K / LG E team in Electrical sub PDT and/or Main PDT, before Feb 28 ( ? ) 5. Achieve a price to LG E in range of $ 60 min to $ 72 max, before Sourcing is completed. (?) Implementation : To be determined Evaluation : GM NA can leverage GM K team to achieve supplier based cost reduction.

3. Need latest part list of capacitor presented on Feb 7,8 in Milford. < File is from Alan Price posting dated Jan 25, 2013

4. Confirmed Feb 15 With Dr JG Lee ( ref : Old Design ) 6 bobbins each 100 uF Y caps incl Snubber out Need updated file as shown on 15th

5. Suresh has sent email to Alan with Qs for Cost Estimating. 1) Manufacturing process flow (start to finish) 2) For each operation: Machine name (equipment manufacturer and model number) Cycle time, number of parts/cycle Number of operators Machine cost (if supplier shared that with you) 3) Film Related Total Film mass per capacitor (for GM), Film mass per bobbin, number of bobbins per capacitor Film thickness (in microns) Number of film layers in each bobbin (of PP, Metalized PP, PET film) 4) Mass Mass of every component that will be in the DC Capacitor - such as film, case, resin, bus bar, etc. 5) Detailed cost for GM part I have requested LG to provide a detailed cost breakdown of the DC Capacitor since we have a gap between supplier price and market price. I will take whatever detail you can get - complete material, labor and burden breakdown, etc.

6. Manufacturability (Information requested from supplier) GM ATC – 9X00xxxx

7. Capacitor Cost Breakdown (Toyota Claims) GM Standard Template

8. Differences between AVX & Panasonic Designs • Capacitor elements: • Panasonic uses (8)100uF capacitor elements with caps lying on flat sides • AVX uses (19) 44uF capacitor elements with caps standing on ends • Film type: Both suppliers use polypropylene film capable of 125C “hot spot” • Film thickness: Panasonic uses 2.5 uM, AVX uses 2.75uM thickness • Panasonic design utilizes space more efficiently, so didn’t require all the allocated design perimeter. • Panasonic design utilizes an “inner wall” that saves extra epoxy • Weight of Panasonic part is ~0.4kg lighter than AVX part with same capacitance because of the reduced amount of epoxy required. • Lead-frames: • AVX uses single lead frame for each cap terminal per Delphi design • Panasonic requested to use 2-piece lead frame connected at middle terminals • Both parts meet Delphi’s requirements of <0.3 mW ESR and <10 nH ESL Security Classification (edit in Header and Footer)

9. Quality and Production Capability Confidential Quality Control Production Volume 2,000,000 （April 2009） ★Panasonic’s Share > 80％ Almost all HEV’s use Panasonic Film Capacitors. ★Zero Defect in field after 2 million capacitors production ★Production Capacity > 800,000 Units/ y 1,000,000 （April 2007）

10. Process Flow of HEV/EV Capacitor Confidential Confidential Strong points of Panasonic’s process Metallization Process ◇All metallization are done in Toyama factory. ◇Precise and fast metallization ◇Precise and fast winding ◇Good contact between metal-spray and metallization to achieve high ripple-current capability Element Process Assembly Process ◇Automated soldering, potting and Electric inspection ◇Traceability by serial-number (element inspection data, lot of film, housing and so on)

11. Metallization Process Confidential Process Major control points Appearance Equipment (Image) Metallization ■Vacuum level ■Resistivity ■Margin width ■Patten dimension Metalizer Master-roll of metalized film Master- roll of raw film Master- roll of raw film Storage ■Temperature ■Humidity ■Time Master-roll of metalized film Slitting ■Slitting width ■Margin width Patterning Mechanics Slit-roll of metalized film Slit-roll of metalized film Slitter Inspection ■Resistivity ■Slitting width ■Margin width ■Pattern dimension ■Appearance To element process Master-roll of metalized film

12. Element Process Metal Line Metal Line Metal spray Confidential Process Major control points Appearance Equipment (Image) Winding ■Off-set of film rolls ■Tension ■Winding length Pressed elements Winding machine Press ■Pressure ■Voltage ■Air pressure ■Distance between spray-gun and elements ■Metal line speed Metal-sprayed elements Metal spray ■Vacuum level ■Temperature ■Time Aging Cleaning ■Appearance Inspection ■Test voltage ■Test current ■Capacitance ■Loss tangent Ａ Voltage, C, tangent Inspection To Assembly process

13. Assembly Process Confidential Process Major control points ■Temperature ■Solder speed ■Time Soldering Assembling ■Appearance ■Mixture ratio ■Volume of resin Potting ■Temperature ■Time Hardening ■Test voltage ■Test current ■Capacitance ■Loss tangent ■Appearance ■Size （pitch of terminals and mounting holes) Inspection Packaged and Delivered To Customers