National Seminar on Remanufacturing Organized by ASSOCHAM Ministry of Heavy Industries Public Enterprises

1. National Seminar on RemanufacturingOrganized byASSOCHAM & Ministry of Heavy Industries & Public Enterprises Imperial Hotel, Delhi 18th September 2009

2. Topics User Expectations Why Reman. Timken Solution Customer value from Reman programs � Timken Cases

3. User Expectations Minimize Capital costs Operate plant and machinery with the lowest cycle cost of components Maximize uptime and productivity Minimize equipment delays and unproductive time Planned maintenance Vs breakdown Plant reliability Improve product quality Maintain minimum inventory of components

4. Why Reman The NASA report suggests that you can back to 74-100% of L10 life of new bearing � if restored properly. We are a little more conservative because there will still be some original stress material still present in the bearing (however it is pushed deeper after grind). This original material though is only designed to carry so many stress cycles. Example of bending of paper clip: clip can only handle so many back and forth stress cycles (bending it). Now if you shift down on the clip from the location that was seeing the cycle � that portion is still seeing some stress but much less than before. However, it is not as if it has never been stressed like a new clip. The NASA report suggests that you can back to 74-100% of L10 life of new bearing � if restored properly. We are a little more conservative because there will still be some original stress material still present in the bearing (however it is pushed deeper after grind). This original material though is only designed to carry so many stress cycles. Example of bending of paper clip: clip can only handle so many back and forth stress cycles (bending it). Now if you shift down on the clip from the location that was seeing the cycle � that portion is still seeing some stress but much less than before. However, it is not as if it has never been stressed like a new clip.

5. Common Questions Will a remanufactured bearing last as long as a new one? In most cases, they will

6. Concern: There is an optimum cost Don�t repair too soon, don�t repair too late! ZONE A: One might argue that a bearing that has seen relatively few stress cycles has not progressed to where the damage from subsurface shearing presents a problem. We would have to concur. For all intent and purposes, and barring anything other than superficial surface damage being present, this bearing could be reconditioned without grinding. If the mill practice is one in which the bearings are pulled on a routine basis, then the choice becomes � will this bearing last me through the next campaign without going into ZONE C. ZONE C: The application or maintenance practices are causing too much damage and considerably more money to replace bearings every campaign. Can you catch bearing while in ZONE B, so that repair to bearing is feasible?ZONE A: One might argue that a bearing that has seen relatively few stress cycles has not progressed to where the damage from subsurface shearing presents a problem. We would have to concur. For all intent and purposes, and barring anything other than superficial surface damage being present, this bearing could be reconditioned without grinding. If the mill practice is one in which the bearings are pulled on a routine basis, then the choice becomes � will this bearing last me through the next campaign without going into ZONE C. ZONE C: The application or maintenance practices are causing too much damage and considerably more money to replace bearings every campaign. Can you catch bearing while in ZONE B, so that repair to bearing is feasible?

7. Timken Solution

8. Range of Services You can select from a range of repair services Recertify: Clean, examine, verify internal clearances, preserve and package Reclaim: Polish using proprietary vibratory process, preserve and package Recondition: Combines Recertify and Reclaim services Remanufacture: Clean, examine, grind raceways, new roller sets, replace major components as required, reset internal clearances, preserve and package

9. Customer Value from Remanufacturing Programs � Timken Cases

10. Coiler pinch rolls of a Hot Strip Mill Market Primary Metals Application Hot Strip Mill The Timken Advantage Timken worked with customer to identify solution to extreme wear in coiler pinch rolls. Timken�s new rolls with Mill Clad steel overlays: � Reduce wear and lengthen service life � Increase coiler uptime and reduce maintenance hours � Reduce roll inventory Results Increased coiler uptime and increased strip quality Reduced Roll inventory Reduced maintenance� 8 mandays every 2wks to every 16 � 20 wks Reduced redressing time for rolls -

11. Machine Tool Market Machine Tools � Horizontal Machining Center Application Cross Roller bearing for table mounting The Challenge Existing bearing requiring repair and machine downtime cost is Euro 30,000 per day New bearing leadtime is minimum 6 months The Timken Advantage Timken turned arround the bearing repair � installed new rollers and race grinding - at its plant in 7 days Results Machine was producing quality product in 7days Frequent downtimes and adverse product quality on operating with damaged table bearings eliminated

12. Mining Equipment Market Mining Application Mining Equipment Repair Operations The Timken Advantage Timken Advantage: Bearing repair, on-site maintenance training, quality products and good customer service help to improve Equipment Service providers performance in serving the mining industry.

13. Bearing Repair - Lafarge Cement Application � KHD Roller Press Bearing Make & Part No. � FAG � 517680A Value of two bearing - $ 102,360 Average life of the bearing � 2 to 3 years The lead-time of new bearing � 12 to 24 months The above bearings has been refurbished and in operation for more than 10000 Hrs. The cost of refurbishment of two bearings - $ 61462 Customer has not purchased any set in year 2008. Value Created $ 40,898 Direct savings No Mill downtime because of bearing availability

14. Bearing Repair - Essar Steel Hot Strip Mill Application � Hot Coil Box Mandrel Bearing Part No. � M272749Assy902B3 and M268749 Assy90118 Value of two bearing - $ 27,500 The lead-time of new bearing � 12 months Customer could remove bearing from the mandrel. Would need to gas cut bearing with potential risk to mandrel Timken Service Engineer designed the fixture and dismantled the bearing without damaging it. Bearings are being refurbished for $ 13,475 Value Created $ 14,075 Direct savings No damage to shaft Mandrel was assembled and put back in service

15. Chock Rebuild � Tinplate Company of India 4 Hi Skin Pass Mill Chock Rebuilding The chocks were scraped by the customer The cost of 4 new chock will be $ 60,000 Operated in mill for more than 12 years New chocks delivery will be 12 to 24 months Set of 4nos. of chocks rebuilt The turn around time is 4 months The cost of rebuilding is $ 14,000 The chocks were sent to customer with UST & Magnaflusk Test report. Currently in Operation

16. Usha Martin Procured used bar Mill from US. (15 to 20 years old) Customer wanted available bearings and chocks refurbished and put back in operation Refurbishment order value $ 50,000