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ZF Transmissions Gray Court
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Introduction
Karl Kehr
� Chief Financial Officer of ZF Transmissions Gray Court, LLC effective July 1, 2012
� Experience:
� 8 years in the aerospace industry in Southern California
� 15 years in automotive industry, including 10 years with Ford Motor Company and 5 years with ZF
� Masters in Business Administration from Chapman University, Orange, CA.
� Relocating to the Greenville area from Cincinnati in the near future
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Agenda
� ZF global facts and figures
� ZF in North America
� ZF Transmissions in South Carolina
� products
� plant data
� manufacturing technologies
� HR strategy and hiring of employees
� questions
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About ZF - History
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ZF Group - Company Structure
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The ZF Group – An Overview 2011 2011/2010
Sales € 15,509 million 20 %
Employees (end of year) 71,488 11 %
Capital expenditure € 1,058 million 82 %
R&D expenditure € 754 million 17 %
121 production companies in 27 countries
8 main development locations in 4 countries
34 service companies and more than 650 service partners
ZF 2011 ZF Group Key Figures
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1915 Foundation of Zahnradfabrik GmbH in Friedrichshafen through Luftschiffbau Zeppelin GmbH.
1970 Foundation of ZF Getriebe GmbH, Saarbrücken.
1973 Volume production start for automatic 3-speed transmissions in Saarbrücken.
1982 Volume production start for automatic 4-speed transmissions in Saarbrücken.
1990 Volume production start for automatic 5-speed transmissions (for BMW) .
1991 Acquisition of the former IFA transmission plant in Brandenburg; in 1998, it is integrated into the Car Driveline Technology division.
1992 Change of Group’s name to ZF Friedrichshafen AG.
1998 Takeover of R&D from VCST continuously variable transmissions at the Sint-Truiden location, Belgium.
1999 Joint Venture between ZF und FORD in the USA.
2001 World premiere: Volume production start of the first automatic 6-speed transmission 6HP26 for passenger cars.
2003 Presentation of the automatic 7-speed transmission (IAA in Frankfurt).
2004 Joint Venture between ZF und SAIC in China.
2005 Presentation of the 7-speed dual clutch transmission (DT) and the hybrid system (IAA in Frankfurt).
2006 Introduction of the 2nd generation of automatic 6-speed transmissions with another 3-6% in fuel savings and even faster shift times (partly below the driver`s limit of perception)
2007 Presentation of the automatic 8-speed transmission 8HP (IAA in Frankfurt).
2008 5 million 6-speed automatic transmissions produced.
2009 Start of volume production of the automatic 8-speed transmission 8HP.
Car Driveline Technology History
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ZF in North America (2011)
ZF in North AmericaLocations
MichiganMichiganWisconsinWisconsin
KentuckyKentucky
North CarolinaNorth Carolina
South CarolinaSouth Carolina
IllinoisIllinois
AlabamaAlabamaGeorgiaGeorgia
FloridaFloridaMexicoMexico
WashingtonWashington
Employees Sales Locations: USA and Mex.
~7,174~7,174~7,174~7,174 $ 2.702 mil. $ 2.702 mil. $ 2.702 mil. $ 2.702 mil. 22222222
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The ZF Transmission Range in P-Division
Automatic Transmissions
Manuals/Dual Clutch
9HP 7DT
8HP S6-45
6HP S6-37/53
Shanghai (ZFTS)
SaarbrückenBrandenburg
FriedrichshafenKressbronn
Greenville
Northville
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9-Speed Automatic Transmission
OptimizationConventional drives
Hybrid drive Electric drive Lightweight design Alternative energies
ZF Product Innovations
ZF as technological leader
8-Speed Automatic Transmission
� Reduction of CO2 emissions by 10 to 16 percent
� Extremely space-saving
� Flexible construction kit system
� Fuel savings of 6 percent
� Can be combined with different inputs and outputs
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2846 North Old Laurens Road, Gray Court, SC, Lauren s County
ZF TransmissionsGray Court (ZFTG), South Carolina
Employees Size Land Start of Production Investment
~1,200+~1,200+~1,200+~1,200+ 950,000 Ft.950,000 Ft.950,000 Ft.950,000 Ft.2222 127 Acres127 Acres127 Acres127 Acres Q1 2013Q1 2013Q1 2013Q1 2013 $ 430 Mil. +$ 430 Mil. +$ 430 Mil. +$ 430 Mil. +
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� 8 speed automatic transmission
� 8 HP 70, 8 HP 70 X rear wheel drive applications (North-South)
ZFTG Products – 8 speed A/T
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ZFTG Products – 9 speed A/T
� 9 speed automatic transmission
� 9 HP 48, 9 HP 48 x front wheel / all wheel drive applications (East-West)
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Customer Status ZFTG
� Chrysler 300 and Dodge Charger
� Transmission: 8HP70 and 8HP70X
� Engines: 5.7L gasoline
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Customer Status ZFTG
� Jeep Grand Cherokee and Dodge Durango
� Transmission: 8HP70 and 8HP70X
� Engines: 5.7L gasoline
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Customer Status ZFTG
� Ram 1500
� Transmission: 8HP70 and 8HP70X
� Engines: 5.7L gasoline; 6.4L gasoline
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Customer status ZFTG
� Summary customers:
� Chrysler for 8 speed and 9 speed, several applications incl. Sedan, SUV and trucks
� 5 other OEM’s included in BP volume
� 2 more OEM’s with high probability to be customers (not included in BP volume)
� almost all major OEM’s in discussion with ZF
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plant data (1)
� plant location: 2846 North Old Laurens Road, Gray Court, SC, Laurens County(on I-385 between exit 22 and exit 19)
� size of land: 127 acres (514.000 sqm)
� size of building: 947.000 sqft (87.000 sqm)(230 m x 380 m)
� extension option: 400.000 sqft (approx.) (38.000 sqm)
� building ready to move in: January 2012
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plant data (2)
� number of employees 1200 + (direct, indirect, salaried)
� current number of employees: 310 (as of September 2012)
� in house production: final test, final assembly, sub assemblies,steel parts incl. ring gears, machining of only one die casting part
� initial capacity: approx. 800.000 transmissions(400k 8HP, 400k 9HP) @ 16 shifts
� investment: $ 430 M +
� SOP: second quarter of 2013
20Manufacturing Engineering Overview
• Groundbreaking 02/012011
• Walbridge - Construction Started 03/07/2011
• Steel Installation Began 05/31/2011
• Main Building Steel Complete 08/25/2011
• Main Building Roof -100%Complete 10/14/2011
• Electrical Sub-Yard - Site Permanent Power Ready 12/05/2011
• North 1/2 of Plant Floors 100% Completed 01/24/2012*
*Ready For Mfg. Equipment Installation
• South 1/2 of Plant Main Electrical Power Complete. 03/01/2012
• Entire Facility (Interior, Exterior & Site Work) Complete 04/30/2012
-All Building Systems & Infrastructure Operational and Commissioned
-Punch List Complete and (C of O) Certificate of Occupancy Granted *
Construction Milestones
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21ZFTG Engineering Overview
Plant: Concept to Reality
Feb 2011 Feb 2012
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ZFTG Site Layout
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ZF Product and Production Strategy
� ZF product strategy:
� technological leadership
� providing highest customer value with innovative products
� ZF production strategy:
� Production of products in the market for the market to minimize currency exchange risks, transportation cost risks (also natural hedging opportunities) and close proximity to customers
� ZF strategy execution:
� Automatic transmissions (A/T) for USA are currently produced in Germany
� ZF’s current and future USA customer base and future opportunities however justifies a local production of A/T’s
� Localization of A/T requires a large investments
� ZF started a site selection process in North America
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ZF’s Site Selection Process
� ZF’s site selection included 70 potential sites in USA and Mexico
� some criteria within the site selection process
� Availability of a site with right size / extension options also for suppliers
� Availability of qualified workforce, work ethics and right to work
� Cost structure (incl. labor cost , energy, logistic cost, cost for land, development, etc.)
� Local training / qualification support (ReadySC)
� Harbor (Charleston) / airports (CLT, GSP)
� Potential future suppliers in the area
� Product engineering / process engineering support organization (CUICAR)
� Support structure from State and County organizations (organization and incentives)
� Further opportunities in the US. S.E. automotive cluster
� Result: Laurens County Industrial Park, Gray Court, SC
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Required Skills
� Total Number of Employees
� 1,200 + at full capacity in 2016
� Overall
� Minimum high school or GED
� One year in a manufacturing environment
� Technical
� Two year degree or equivalent experience in position
� CNC programming (highest level)
� Semi-Skilled
� High School or GED
� One year in a manufacturing location
� One to two years of CNC experience (in Machining area)
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Plant Overview
Main Offices
Electrical &
Mechanical
Spare Parts
Storage
Maintenance
Supplier
Quality
Shipping
NorthParking
Employee
Entrance
Main Entrance
Truck Entrance
Receiving
Cafeteria
Storage
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Machining & Heat treat: General Information
� 347,543 sq. feet
� Planned cycle time: 35 seconds
� 7 Basic parts
� Sun Gear
� Ring Gear
� Planet Carrier
� Input Shaft
� Output shaft
� Transfer gears
� Planet Gears
� Fully automated heat treat
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Machining & Heat Treat: Layout
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Machining & Heat Treat: Layout - Typical Flow
TURNING/DRILLING/REAMTURNING/BORING
BUSHING PRESS
LASER WELDING
FINAL INSPECTION
LOAD
U-SHAPE WASHER
HIGH PRESSURE WASHER
ROBOTIC DEBURRING
100% BORE INSPECTION
SPC Station
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Machining & Heat Treat: Technologies
� Turning (Green/ Hard)
� Milling
� Drilling
� Welding (Laser)
� Washing (U-Shape, HP, Batch)
� Balancing (Auditing,
Correction)
� Induction hardening
� Extrude Honing
� Presses (Automated Hydraulic)
� Broaching
� Scudding
� Heat Treat
� Robotic Deburring
(automated)
� ECM Deburring
� Kuka Robots
� Hobbing
� Grinding
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Assembly & Test: Plant Layout
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Assembly & Test: Technologies
� Robotics - KUKA
� Bolt torqueing – Atlas Copco
� Laser Marking - Ricther
� Vision systems – several types
� Washing (Traditional with Robotics)
� Helium Leak Test – HOF, Kuka
� Test Benches - ZF Passau
� Servo Presses (Tox)
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= Installation in Progress
Equipment InstallationProgress
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Thank you! Any Questions?
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