Stainless Steel in Exhaust Systems Angel Ramirez

Transcription

1 Stainless Steel in Exhaust Systems Angel Ramirez London, September 3 rd 2013

2 Faurecia Group Overview 2012 key figures 94,000 employees 320 sites 34 countries Group revenues: 17,3 billion 47 R&D centers 5,500 R&D engineers and technicians 460 patents filed in 2012 Annual R&D budget: 943 millions 1. Bosch 2. Denso 3. Continental 4. Magna 5. Aisin Seiki Johnson Controls 8. Hyundai 9. ZF 10. Delphi 11. Valeo 12. TRW 13. Lear 14. Yazaki 15. BASF 16. Sumitomo 17. Toyota Boshoku 18. Calsonic Kansei 19. Cummins 20. Autoliv The world's top automotive equipment suppliers (2011 revenues bn) 16.2 N 6 worldwide equipment supplier 2

3 Faurecia Group 4 world leading businesses 2012 Total Sales n 2 worldwide 1.8 bn Group revenues 17.3 bn n 1 worldwide 6.1 bn n 1 worldwide 4.3 bn n 1 worldwide in mechanisms 5.1 bn 3

4 Faurecia Emissions Control Technologies The worldwide leader 19, 800 employees 79 operations (components plants &JIT) Complete lines 11Mio parts/year 7 R&D centers 22 countries Number 1 in emissions control market Widest geographical presence for manufacturing and engineering Large portfolio of products and technologies for every type of vehicle and engine Global program management Innovation focused on customer needs Manifolds 4 Mio parts/year Catalytic converters 23 Mio parts/year Diesel Particulate Filter 3 Mio parts/year Mufflers 20 Mio parts/year 4

5 Faurecia Emissions Control Technologies Products & technologies for every application Entry Segments Ford Fiesta VW Polo Peugeot 2008 Hyundai HB GM Aveo Dacia Duster Mid- Range Segments VW Tiguan Ford Kuga Toyota Auris Kia Cee d Volvo S40 Jeep Liberty Premium Segments Mercedes S-Class Audi A8 BMW X5 Range Rover Evoque Ferrari Italia Harley Davidson Commercial Vehicles Ford Transit GM Silverado John Deere DAF truck Volvo Off-Highway HINO Truck 5

6 Faurecia Emissions Control Technologies Production & sales balanced across major regions NORTH AMERICA 1 R&D center 10 Plants 2 JIT EUROPE 2 R&D centers 19 Plants 16 JIT 7 R&D Centers 50 Plants 29 JITs Asia 20% IOP & Asia IOP 7% 2012 Sales 39% Europe 32% 2017 Sales 34% Europe NAO 34% NAO 34% MERCOSUR 1 R&D center 3 Plants 6 JIT ASIA 3 R&D centers ASIA 18 Plants 5 JIT 6

7 Faurecia Emissions Control Technologies A strong partnership for Commercial Vehicles DOC/DPF systems for Euro VI Complete CVE product offering Off Highway On Highway Partnership Faurecia-Cummins Thermal regenerators Selective Catalytic Reduction systems Truck Off road After-Treatment engineering and manufacturing World leader in medium-to-heavy duty on and off-road diesel engines More than 1m engines produced in 2012 Strong positions in North & South America, India and China System integration Marketing and sales 7

8 Faurecia Emissions Control Technologies Innovation focused on customer needs Innovation Directions: Emissions Control Acoustic Performance Energy Recovery Weight Reduction 8

9 Faurecia Emissions Control Technologies Emissions Control Local Emissions Solutions developed by a Global Expert Network CAGO TOOL Manifold stress simulation NH3 distribution & velocity analysis Complete Emissions Controls management through wide range of key products Tubular Maniverter SCR Compact Bluebox Fuel Vaporizer LP EGR valves Innovative ideas for 2020 and beyond GPF (1) Advanced De-NOx ASDS Thermal & Acoustic insulation Solutions for all engines to meet the most severe emissions legislation including Euro 6.2 (RDE) & USA LEV III/Tier III (1) Gasoline Particulate Filter 9

10 Faurecia Emissions Control Technologies Acoustics Performance Best-in-class acoustic expertise supported by in-house software development & test equipment GT-Power, AMELI Acoustic imaging Anechoic Chamber Complete exhaust sound management capability through wide range of key products Pipes Mufflers Valves EDST (1) Demonstrated competencies to deliver customized sound for all types of engine and vehicle Chevrolet Silverado Golf R32 Ferrari 458 The most diversified portfolio of passive and active solutions to meet the demand for cost-effective acoustic performance systems (1) Exhaust Dynamic Sound Technologies 10

11 Faurecia Emissions Control Technologies Energy Recovery Proven know-how in designing the exhaust system architecture to optimize the performance of the heat recovery system Exhaust integration expertise Thermal system modeling Rankine & TEG test bench Heat to Heat technologies to address cold start and improve thermal system efficiency EHRM (1) Ford C-Max Hybrid Compact EHRS Up to 6% on hybrids - cold Improved passenger comfort Heat to Power technologies to generate power out of exhaust heat Up to 1.5 kw can be 120km/h Rankine System TEG (2) Rankine test bench results Proven capability in recovering energy from the exhaust line to improve vehicle fuel consumption and lower CO2 emissions (1) Exhaust Heat Recovery Manifold (2) ThermoElectric Generator 11

12 Faurecia Emissions Control Technologies Weight Reduction Emissions Control Acoustic Performance Gasoline fabricated manifold BMW 2.0LGTDI Gasoline Lightweight Hot End GASOLINE Maniverter Catalytic converter Actuated valve - 20% (1) Audi S8 Pipe Muffler Adaptive valve Diesel fabricated manifold Applies to all Wall thickness reduction GMC Silverado Audi V6 3.0L Diesel Lightweight Hot End SCR Compact Bluebox Applies to all DIESEL Manifold DOC, DPF (3) Selective Catalytic Reduction - 30% (2) Pipe Muffler Brazed cold ends Applies to all Lock-seam => Welded muffler Applies to all Applies to all Ford B-Max Recognized expertise for best-in-class lightweight exhaust systems using thin wall materials, innovative joining technologies and acoustic valves (1) 3-cyl 1.0L turbo 100cv (2) 4-cyl 1.6L turbo 110 cv 6.2 SCR - (3) Diesel Oxydation Catalyst & Diesel Particulate Filter 12

13 Stainless Steel in Exhaust Systems Grades used Fabricated manifolds ( 1000 C ) Panel: 429 ~ 441 < 444 < 309 Pipes Panel : 409 < 439/441 < coated steels Catalytic converter / DPF Panel : 409 < 429 ~ 441 < < 309 Front muffler Panel : 409 < 439/441 < 304 Rear muffler Panel : 409 < 439 < < coated steels C C C Hot End Cold End 13

14 FECT 2013 Demand *Stainless Steel: Forecast for 2017 is to reach 500Kt 410K metric tons North America t Europe t Russia t India t S. Korea t China t Thailand t Mercosur t S. Africa t *FLAT CR including Managed Direct, Tier2 & tubes. FECT also buys 7Kt Welding Wire & 7Kt Carbon Alu 14

15 FECT 2013 Demand *Stainless Steel Split by grade Other Ferr. (5 %) 304 (8 %) Other Aus. (1%) 441 (14 %) 409 (43 %) 439 (19 %) 409AL (10 %) Ferritic grades represent >90 % of FECT volumes 441 increase in Asia and NAO, 304 challenged on Cosmetic corrosion *FLAT CR including Managed Direct, Tier2 & tubes. 15

16 FECT 2013 Demand *Stainless Steel TUBES: Forecast for 2017 is to reach 190Kt 153Kt North America t Europe t Russia t India t S. Korea t China t Thailand t Mercosur t S. Africa t *Welded tubes made from FLAT CR STS included in total FECT 410Kt. 16

17 Light Vehicle market drivers for Exhaust Systems 1 2 LV volumes continue to grow at 4.3% CAGR ( ) Emissions legislation deploys globally 3 4 which leads to CO2/fuel economy legislation is strengthening deployment of hybridization and down-sizing 5 OEMs pursuing Global engines/platforms strategy 17

18 Millions 1 Light Vehicle market drivers for Exhaust Systems Light Vehicle volumes (<3.5 Tons) from IHS Source: IHS NAO Europe China Japan India Korea ASEAN Brazil Russia ROW CAGR Europe +2.6% NAO +2.7% China +8.9% India +10.1% Brazil +5.9% Global +4.3% Global demand for LV is still strong with China leading the way. 18

19 2 Light Vehicle market drivers for Exhaust Systems Emissions legislation rollout worldwide for light vehicles Euro 5 Euro 4 Euro 6.1/6.b Euro 5 Euro 6.2/6.c Euro 7? Federal regulations California + 13 states LEV II Tier 2 LEV III Tier 3 Nationwide gasoline Euro 4 Euro 5? Nationwide Diesel Euro 4 Euro 5? Bejing Shanghai Guangzhou Nationwide Delhi + Big cities Euro 5 (Gasoline) Euro 3 Euro 4+OBD -11 cities + NCR Euro 4+OBD -50 cities + NCR Euro 4 Euro 4 Euro 5 Emissions legislation deploying globally 19

20 3 Light Vehicle market drivers for Exhaust Systems CO2/Fuel Economy Legislation is strengthening g/km Average CO2 emissions from new passenger cars Target US CHN Achieved 160 Target Mid term 2020 Longer term Target Target Target 2025 Longer term 95 75? EUR Target 90? Target Target Time (year) 2010 C4 II 2010 C4 II Demand for lightweight technologies will increase Note 1: US targets CAFÉ fuel economy numbers of 35.5 mpg in 2015, 40 mpg in 2021, 54.5 mpg in These are rough conversions into CO2 numbers Note 2: China targets fuel economy numbers of 4.7L / 100km by These are rough conversions into CO2 numbers 20

21 4 Light Vehicle market drivers for Exhaust Systems Hybridization and down-sizing are deploying By 2020, - 17% of vehicles will run a hybrid powertrain - 99% of vehicles will still have an ICE Source: IHS/Roland Berger From 2012 to 2020, - 2 and 3 cylinder engines grow at 28%/year - 4 cylinder turbo engines at 8%/year Source: IHS/Roland Berger 21

22 5 Light Vehicle market drivers for Exhaust Systems Increased number of common platforms and modules requires FECT to be more aggressive on first RFQs Scope & complexity of standardization OEM maturity level in modularization strategies Most advanced OEMs Standardization strategy 1 Carry-over 2 Platforms 3 Modules Scope : basic components Scope : common technical perimeter to several models (underbody) Scope : complex systems / subsystems dedicated to an entire function Increasingly important to win first platform/module in order to be present on next platforms/modules Source: Global Insight, Roland Berger analysis 22

23 Commercial Vehicle market drivers for Exhaust Systems Emissions legislation rollout worldwide for On-Highway vehicles Regulation in different geographies China Euro III Euro IV China - (Beijing, big cities) Euro IV Euro V India Euro II Euro III Euro IV India - (Metro) Euro III Euro IV Euro V Brazil Euro III Euro V NAM EPA 10 EPA 13 EPA 14 EPA 16 EPA 17 Western Europe Euro V Euro VI Japan JP-9 JP-13 JP-16 Russia Euro III Euro IV Euro V Timing of actual compliance lags timing of regulation in developing markets 23

24 Stainless Steel demand in Exhaust Systems future Messages of today s presentation Automotive demand growth growth for Light and Commercial vehicles continues to grow FECT growth targeted to be higher than market FECT remains an strategic customer for STS Mills No. 1 global Automotive exhaust supplier Technology leadership - Innovation 410Kt in 2013: Major tonnage buy of STS worldwide Emissions Regulations deploying globally Emission Legislations deploying globally CO2/fuel economy legislation strengthening Hybridization and downsizing trend Grades usage trend High temperature grades for fabricated manifolds Ferritic incremental usage vs. Austenitic Lower cost alternative grades development Thickness reduction Current major FECT usage is 1.5, 1.2 & 1.0 mm Lightweight requirement will drive increase usage of lower thickness 0.8mm. and 0.6mm. Supplier competitiveness to improve OEMs pursuing Global engines/platforms strategy requires more aggressive 1 st RFQs Keep optimizing the supply to our Tier 2s to ensure competitiveness and profitability (Best landed Cost) 24

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