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Welcome to Synerject. Continental Automotive France SAS and subsidiaries 6 locations / 5 legal entities (3700 employees). Production Plants R&D Centers . Continental Automotive France SAS Continental Automotive Rambouillet SAS Continental Automotive Trading SAS
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Continental Automotive France SAS and subsidiaries6 locations / 5 legal entities (3700 employees) Production Plants R&D Centers Continental Automotive France SAS Continental Automotive Rambouillet SAS Continental Automotive Trading SAS Continental Automotive Hambach SAS * Hambach (150 empl) Paris Rambouillet (650 empl) Toulouse Head Quarter: 2600 employees Location opened in 1979 2 other plants nearby: Foix & Boussens Toulouse (2600 empl) Boussens Foix * Carve out process of Hambach activities launched out of CA Trading France SAS
Continental Automotive Toulouse, Foix, Boussens customers Continental Automotive in France is a supplier and a system partner for Automotive Manufacturers
Daily production : 60,000 units Toulouse Mirail Plant Plant Management O. Miquel, B. Caldairou Key figures Start of production 1979Manufacturing area 7200 sqmLogistics area 6000 sqmManufacturing lines (SMD) 8 Manufacturing lines 14 3 teams and 1 week-end team Products Electronics for Body & Security (body controlers, car access, tire pressure), Chassis Components (suspension, steering, Tier Two Electronics), Aftermarket Certifications Main customers ISO 9001 version 2000 ISO 14001version 1996 ISO/TS 16949 version 2002 Renault, Peugeot, Citroen, Audi, DC, Delphi, Ford, GM, Jaguar, Hyundai, KIA, Land Rover, Mazda, Nissan, TRW, Volvo, VW
Automotive Quality Laboratoriesmain tasks Ensure Transparent Responsibilities! Pre-DV, DV, PV Reliability Testing Set-up and performance of Reliability Testing – Thermal, Mechanical, Vibration, Corrosion, Water Spray, and NVH - Consulting on Product Improvements Pre-DV, DV, PV EMC Testing Set-up and performance of EMC Testing – Emissions, Susceptibility, Electrical Transient, and ESD - Consulting on Product Improvements Development Test Validation Engineering Validation Product Management – Test Plan Development with Internal and External Customers, Test Reporting and Non-conformance Analysis/Improvement Support TEST LABS EMC & Reliability Focus on DV/PV TEST Shared equipment utilization for Engineering Test Engineering Focus on Product/Design Development & Improvement Dedicated BU Test Labs Validation Test Equipment Engineering Validation Test Equipment Project Management – Development of Test Equipment/Systems Required to Simulate End Application during Validation Testing Analysis Lab Physical and Chemical Analysis of Components, Materials, and Products Close Cooperation Metrology Management of Calibration ESD Manufacturing Support Manufacturing support for ESD compliance EMC Modeling Engineering EMC (Spice) Modeling of Components and Circuits during Product Life Cycle. BU Engineering Quality Automotive Reliability Modeling Engineering Finite Element Analysis in Support of Development Engineering
Automotive Quality LaboratoriesEMC laboratories activities • Mission : ElectroMagnetic Compatibility test facilities for evaluation and qualifications in design development and production phases • 1200 test days/year charged 100% to R&D and Support Projects. • Test costs about 40% cheaper than free market • Products quality continuous improvement support. • AEMCLRP / ISO17025 : Accreditation Laboratory Recognition for North American car manufacturers and automotive international standards
Automotive Quality LaboratoriesReliability laboratories activities Climatic / Humidity Water tightness • Mission : REL test facilities : simulation of environmental stress for evaluation and qualifications in design development and production phases • 1600 tests/year charged 100% to R&D and Support Projects. • Test costs about 30% cheaper than free market • Products quality continuous improvement support. • ISO17025 Accreditation Vibrations Corrosion Electrical tests HALT
Automotive Quality LaboratoriesMaterials laboratories activities • Mission : Controls of materials and manufacturing processes, Failure analysis and field return analysis, Controls of products after environmental tests (DV / PV) • 1200 tests/year charged 100% to R&D and Support Projects, manufacturing reactivity • Manufacturing reactivity • Test costs about 30% cheaper than free market Microsections, visual inspection X rays 2D 3D SEM (non organics) Acoustic microscopy Solderability, Fluorescence X Thermal mapping Calorimetry FTIR (organics)
Automotive Quality LaboratoriesSpecific central quality support • Dimensional measurements • EMC / Mechanics / Thermal simulations • ESD manufacturing support • Metrology management • Reliability engineering
Specific design tools • SABER: simulation tool for analog and behavioural design • VHDL / Modelsim: Simulation tool for digital design • Specific validation tools • Prober: test tool for in-circuit inspection and failure analysis • Thermojet: test tool for 3 temperatures characterization Specific tools for design and test System & Technology AutomotiveAsics, Micro-Electronics Development
PowertrainTest Center • Mission: support Powertrain for EMS Systems Integration, Development & Tuning: Engine & Vehicle Preparation Engine & Chassis Dyno Tests Road Tests & Trips support • 7 Development Engine Dyno Cells 1 Emission Chassis Dyno ( Euro V, SULEV ) 1 Climatic Chassis Dyno 2 Climatic Chambers 2 & 3 Shifts operations 20 000 h ED Tests / Year 10 000 h CD Tests / Year • Tuning Expertise, Methodologies Development, Test Equipment up to date, Process orientation • ISO/TS 16 949 & ISO 14 001 Certification • World Wide Test Center Organization: reduce development costs, support BU worldwide, transfer development programs Customer
Passenger and Light Truck Tires Chassis & Safety Interior ContiTech Powertrain Commercial Vehicle Tires • Original Equipment • ReplacementEurope • Replacement The Americas • ReplacementAsia • Two-Wheel Tires • Truck Tires Europe • Truck Tires The Americas • Truck Tires Asia • Industrial Tires • Air Spring Systems • Benecke- Kaliko Group • Conveyor Belt Group • Elastomer Coatings • Fluid Technology • Power Transmission Group • Vibration Control • Other Operations • Body & Security • Connectivity • Commercial Vehicules & Aftermarket • Instrumentation & Displays • Interior Modules • Multimedia • Electronic Brake Systems • Hydraulic Brake Systems • Sensorics • Passive Safety & ADAS • Chassis Components • Gasoline Systems • Diesel Systems • Transmission • Electronics • Sensors • Actuators, Motor Drives & Fuel Supply • Hybrid Electric Drives • Turbocharger • Test Center S&T A – Quality Laboratories Automotive S&T, A – Quality Laboratories Automotive Support Functions "Automotive" interdivisions Support Functions « Automotive »interdivisions Asia / North America Regions OrganizationDivisions and BUs represented at Toulouse Toulouse Customer
Company Overview • Established since 1997 • A leading supplier of electronic engine management systems, modules, and components for both 4-stroke and 2-stroke engines in port and direct injection applications • Organized in 4 segments to address the individual customer and market needs MARINE 2&3 Wheeler Utility RECREATION Sales (2010) US $106 million Employees (06/30/10) 282 worldwide Worldwide presence 6 locations in 4 countries on 3 continents
1997 1998 1999 2000 2001 2002 2004 2005 2003 2006 2007 2009 2008 Synerject History JV established to design and manufacture Fuel Rail Assemblies for the Orbital Combustion DI system on Motor Scooter and Marine & Rec vehicles Company expanded to include Engine Management Systems for Port-Injected Two-Wheel vehicles Company expanded to include all of Siemens VDO EMS for non-automotive and EMS for Marine, Snowmobile, and ATV Company acquired low-volume high-end Electronics facility in Delavan Wisconsin USA Established Production and Applications Center in China Production launch M3A module in Changchun China Synerject change of control
Continental in the World Nearly 190 sites for production and R&D in 35 countries. Headquarters in Hanover, Germany. Status: January 2009
SynerjectOrganization Chart CEO T. Bellon 2/3-wheeler LE T. Bellon Recreation S. Tagliante Finance & Administration L. Johnson CFO Synerject LLC L. Johnson Synerject SAS S. May Synerject China Yang Che Utility M. Sokop Marine D. Kilgore Segment with P&L BD/Sales/StrategyL. Fabre EngineeringF. Brun OperationsD. Kilgore Purchasing & SQMS. May Business ControllingL. Johnson
Toulouse France Synerject Locations Synerject Changchun October 2006 Delavan Wisconsin USA Changchun China Chongqing China Newport News Virginia USA Pisa Italy Taipei Taiwan Bangalore India Synerject Locations Regional Customer Support
Our System Platform & Technology Segment DI M3 DI HPDI Standalone case Marinized compatible Drive by wire Torque structure 6 cylinders Segment D 4 cylinders M3D Standalone case “D” Drive by wire (ETC) Torque structure 96 pins IPX9 (Marine) 3 cylinders Segment C Segment B 2 cylinders Segment A Segment L M3B Standalone case B or integrated air module 36 pins IP67 M3C Standalone case “C” MTB 48 pins IP67 M3A IAM 32 Pins IP67 M3L IAFM + immo 12 Pins IP67 1 cylinder High end motorcycles & recreational applications Marine Outboard Innovative recreation 4S&2S DI scooters & ATV & motorcycles& Utility 4S scooters & light motorcycles & utility Middle range motorcycles Low end recreational
Major Customers 2010 Total turnover in 2010= 105 Mil USD
Sales By Segment 2010 Total turnover in 2010= 105 Mil USD
Recreation & Marine market trends • Six month 2011 vs. 2010 : • Large Motocycle: WW market shows a modest recovery nearly +3% to +4% . • Eu market : Sales of >750 cc slightly up +2%. But down -16% for segment 125cc to 750cc • US market : > 650 cc increase about +3.8% • Off road sales continue to decline in US : -17% • Sport bike slight increase : +2% • EU OEM are doing much better then Japan OEM • Japan Motorcycle production ( > 250 cc ) decrease of -14% • ATV: stable market, no sign of recovery • SSV: solid growth . Mainly for Polaris • Snow: slightly up . BRP still leading • The marine market is continuing in the recovery phase; however, some signs of a slowdown are present.