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Make Every School Bus Better.

Make Every School Bus Better. Thomas Bus Oct 4, 2011 Steve D Goss Sanjay Kumar Jim Lannan. Agenda. Update on successes IC Bus ‘Fluid’ Economy Claims Cummins Fuel Economy How to sell Cummins. School Bus Industry Data.

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Make Every School Bus Better.

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  1. Make Every School Bus Better. Thomas Bus Oct 4, 2011 Steve D Goss Sanjay Kumar Jim Lannan

  2. Agenda • Update on successes • IC Bus ‘Fluid’ Economy Claims • Cummins Fuel Economy • How to sell Cummins

  3. School Bus Industry Data • Industry data suggests a 5% gain in Cummins market share (50% to 55%) • Recently gained business with largest bus customer

  4. IC Bus ‘Fluid’ Economy Claims • IC Bus published report of fuel economy testing stating ‘up to a 4.5%’ advantage vs Cummins • Cummins responded to claims outlining the points in question including: • Transmission shift calibration selections • Aftertreatment regeneration ‘Fluid Economy’ also ignores the price differential Avg. Diesel Price $3.80 Avg. Bulk DEF Price $2.85

  5. Transmission shift calibrations • IC Bus did not outline what shift calibrations were used during testing • Cummins testing validates that proper selection can result in significant fuel economy gains

  6. Aftertreatment Regeneration • Typical regen cycle on MF 7 at approx. 135 miles • Same distance as test • More EGR = More Soot Generated = More Regens • Regenerations require the use of more fuel thus diminishing overall fuel economy

  7. ‘Fluid’ Economy • IC’s claims of ‘fluid’ economy inaccurately represent total cost of ownership • No mention of DEF consumption thus inability to analyze actual DEF usage for test • Differences in DEF and diesel fuel pricing vary significantly so need to be analyzed separately

  8. Cummins Fuel Economy • ‘Others Test. We Deliver’ • Cummins and Thomas Bus both currently testing

  9. ISB Fuel Economy Tops DTNA Testing Freightliner M2 106 with Cummins ISB (EPA 10) Vs. International Durastar 4300 with MaxxForce DT (EPA10) Result • 8.5% Better Fuel Economy • 2 Regens for ISB Vs 10 for MaxxForce DT in the 14 hour test period

  10. In Cylinder NOx Control Challenges • Fuel economy significantly compromised • Increased risk of EGR condensation • Significant increase in heat rejection • Complex system integration • Driver satisfaction significantly compromised • Power density and torque limitations

  11. In Cylinder NOx Control Challenges • 5-9% disadvantage • Combustion efficiency degradation: • Higher engine pumping losses • Increased intake & exhaust manifold pressures • Increased Particulate Filter regenerations Fuel Economy Significantly Compromised

  12. In Cylinder NOx Control Challenges • Higher EGR flow produces excessive acidic condensation • Power cylinder corrosion • Rapid deterioration of lube oil • Reliability and durability compromised Increased Risk of EGR Condensation

  13. In Cylinder NOx Control Challenges • 20% increase • Higher EGR flow: • Multiple EGR coolers on & off engine • Larger vehicle cooling package • Major redesign of radiator / Charge Air Cooler / Fan systems Significant Increase in Heat Rejection

  14. In Cylinder NOx Control Challenges • Higher EGR flow • Air handling system • Vehicle cooling system Complex System Integration

  15. In Cylinder NOx Control Challenges • Higher EGR Flow • Throttle Response Driver Satisfaction Significantly Compromised

  16. In Cylinder NOx Control Challenges • Deterioration of 50 – 100 hp for same displacement • Higher EGR flow & EGR controls compromises engine performance Power Density and Torque Limitations

  17. Bus Owners Have Two Choices for 2010 Clean Air DPF DOC Catalyst AMOX Cat DPF Doser Tank DOC Advanced EGR Intercooler Radiator Higher heat rejection: Larger Radiator Larger Charge air cooler EGR + SCR After-Treatment System Setup

  18. Emissions Control Technology

  19. Acidic pH The Facts about the Fluid – DEF Properties • DEF is safe to handle and store • Non-toxic • Non-polluting • Non-flammable • DEF freezes at 12° F (-11° C). However, frozen DEF does not impact start up and normal operation of the vehicle • When stored at extreme temperatures, neither DEF nor Urea become toxic • DEF is slightly alkaline with a pH of approximately 9 DEF

  20. DEF - Myths & Facts • Navistar’s claim of ammonia level being close to 1000 ppm in a near empty DEF tank is a ‘stretch of imagination’ • DEF, when heated and maintained at a constant temperature 120 degrees Fahrenheit, will very slowly start to form small amounts of ammonia • It would take over two years at this constant temperature to convert DEF into levels of 1000 ppm of ammonia • Such a situation can be probably modeled in ‘laboratory setting’ but not in the real world

  21. Cummins ISB6.7 vs Navistar MaxxForce 7Competitive Comparison

  22. Cummins ISB6.7 vs. MaxxForce 7

  23. Competitive Comparison Summary

  24. Designing For the School Bus Market • Reliability • Total cost of ownership • Low maintenance • Safe Operation • Sociability • Performance • Weight/space • Minimal driver training • Ease of operation • Information systems • Emissions compliance

  25. Cummins Diesel Power

  26. ISB6.7 & ISC8.3 Features • Improved combustion system • Advanced VGT Turbocharger • Improved cooled-EGR subsystem/cooling circuit • Fully integrated electronic controls • New Cummins Aftertreatment System

  27. ISB6.7 & ISC8.3 Customer Benefits • Best-in-Class Fuel Economy • Improved Reliability • Minimal Installation Impact • Stronger Performance • Increased Power Density

  28. Cummins Natural Gas Power

  29. ISL G Product Features and Benefits • 8.9L Stoichiometric Cooled EGR engine with spark ignition • In production since mid-2007 • Low emissions • Diesel-‘like’ Performance, Reliability and Durability • Over 80% parts commonality with ISL9 • Compatible with CNG, LNG, or Biomethane (RNG)

  30. Three Way Catalyst Aftertreatment Passive device Packaged as a muffler Maintenance-Free Stoichiometric Combustion Cooled EGR Same rated speed as ISL9 diesel 30% more torque at idle 5% better fuel economy 2010 ISL G Natural Gas

  31. Integrating Critical Subsystems Filtration and Diesel Exhaust Fluid Electronic Controls Aftertreatment System Fuel Systems Turbochargers Combustion Technology

  32. PowerSpec • Software Application • Provide gearing recommendation • Customize engine ‘specs’ • Collect valuable trip information • Free to download and use www.powerspec.cummins.com

  33. INLINE™ adapter • Cummins datalink adapter used in conjunction with PowerSpec • Allows user to: • transfer feature parameter settings • download trip information • INLINE™ 5 kit (part number: 4918416) includes all necessary parts to connect the vehicle to a laptop

  34. Make EveryTM School Bus Better. • Better Fuel Economy. • Up to 3% better than our ’07 ISB and ISC • Joint testing underway on EPA 2010 product • Better Performance. • Improved driveability and throttle response • Better Reliability. • Best-in-class durability and dependability • Better for the Environment. • Near zero NOx and PM emissions • Improved MPG results in smaller carbon footprint

  35. Saf-T-Liner EFX

  36. Common Parts with HDX means faster design cycle Sub-system ID (estimated number of parts to be eliminated ~100) Destination Sign (20) Front Roof Cap (6) #2 Hood (2) Clearance/Marker Lights (6) Windshield (3) Wipers (15) Header Height/Drip Rail (4) “A” Mirrors (8) Hazard Lights (4) “B” Mirrors (8) Headlight & Bezel (4) Bumper (10) WalkGate (8) 00000-00-Thomas Built Buses Standard Template.ppt

  37. Driver Focused Improvements - Storage • Added driver’s storage to right side dash • Can be used for safety equipment storage or for personal items 00000-00-Thomas Built Buses Standard Template.ppt

  38. Driver Focused Improvements - Visibility • Improved visibility • HDX windshield • Larger driver’s side window • Argosy headlights • Running lights standard 00000-00-Thomas Built Buses Standard Template.ppt

  39. Driver Focused Improvements - Visibility • Improved defrost capability 00000-00-Thomas Built Buses Standard Template.ppt

  40. Technician Focused Improvements - Access • Headlight doors and removable grill provide easy service access • Lights • Wiper motors and linkages • Washer fluid • Power steering reservoir • Defrost heater relays 00000-00-Thomas Built Buses Standard Template.ppt

  41. Technician Focused Improvements - Access • Lower driver side access panel for chassis PDM’s 00000-00-Thomas Built Buses Standard Template.ppt

  42. Technician Focused Improvements – Misc. • More reliable components should translate to fewer replacements • Increased parts commonality means less parts for technician to maintain • Bus can still be jacked up by front bumper 00000-00-Thomas Built Buses Standard Template.ppt

  43. Family Look HDX EFX 00000-00-Thomas Built Buses Standard Template.ppt

  44. EFX Status Gate 9/8 Status: Passed (May 9th) Gate 7/6 Status: Passed Scheduled SOP: Q1 2012 Project Budget approved. Bus to be showcased at NAPT in October. Estimated start of production 1Q2012 Pilot/Preseries • We’ll be soliciting orders within the next month • Will come with new sales codes – WebEx will be scheduled to assist in ordering process • Will come with $300 cost increase Design Validation • Cooling passed. • FEA and fatigue analysis in progress. • Defrost testing planned for early October • 6000 mile durability to begin mid-September at Bosch Proving Grounds. 00000-00-Thomas Built Buses Standard Template.ppt

  45. Questions? Thomas Built Buses Dealer Sales Meeting 2012

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