Activities of Autocomponents Division Autocomponents Division 1000 км 600 км Санкт-Петербург Москва Н. Новгород 1400 км Russia Division activities are aimed at manufacturing and sale of autocomponents and industrial products The production site is located in Nizhny Novgorod Autocomponents Division employs about 10 thou. people Autocomponents Division ensures most part of GAZ Group enterprises by autocomponents Our partners - major enterprises of Russia, CIS and non-cis countries Autocomponents Division is one of the largest manufacturer of autocomponents in the RF and CIS countries. Revenue of the Division in 2013 made up 517 Mio Euro. 1
Business of Autocomponents Division Success factors in detail Chassis and Power Train systems Driving and non-driving axles Axle components Steel stamped wheels Clutches Springs Control systems Brake systems Steering systems Rough part production Iron castings Forged parts Aluminum and other non-ferrous castings Tooling Tools and accessories Dies and press-molds Body Stamping Cargo platforms Frames Fuel systems Body armature JV Exhaust systems (JV Bosal-GAZ) Fasteners (JV Bulten-GAZ B.V.) 2
Autocomponents Division Выручка, Revenue, Mio млн. RUR руб. 20 876 21 769 23 191 23 332 23 303 Current Division 16 214 OEM 10 198 OES БРАНОРОС 6% 14% 6% 1% 5% 16% 16% 18% 16% 2008 2009 2010 2011 2012 2013 JV Outside customers Other Diversification of customer portfolio and development of the key business lines is a strategic target of Autocomponents Division. 3
Driving and non-driving axles Main product mix Driving and non-driving axles of light commercial vehicles and buses; Suspension modules of vehicles Production of assemblies and modules is a separate hightechnology site, oriented at full technology cycle of production: machining, stamping, heat treatment, assembly-welding and painting. The biggest production of driving and non-driving axles in Russia (2 plants): Automobile Units Plant (Nizhny Novgorod) axles and suspension modules for LCV and LDT. Kanash Automobile Unit Plant heavy duty axles Possibility of forging and stamping the base suspension modules; Competitive price of final product; In-house blanking production. Conveyed and bench assembly; In-process tightening torque control; Finished products bench testing; High-accuracy СNС machining Capacities Driving axles - 207 thou. pcs. per year Non-driving axles - 157 thou. pcs. per year Suspensions 74 thou. pcs. per year 4
Axle components Brake discs Component of brake system: brake disks Availability of technology and experience in production of disc type brakes for passenger cars and trucks Load-bearing and main parts of axles Components of vehicle axles (axle housings, axle shafts, differentials, reduction gear-boxes, hubs); Components of vehicle suspensions (sub frames, arms, beams, knuckles); Sets of main gear pair (accuracy 4-5 accuracy grade in accordance with DIN 3962). Equipment: 2-spindle turning machining center «Hessap» (with max. diameter of machining up to 450 mm) Capacities: 966 thou. pcs. per year Mazak machining center Equipment: CNC machines of leading global companies «Klingelnbеrg» and «Boeringer» (Germany), which allow to produce final drive pinions of driving axles in accordance with worldwide standards Designing of transmissions is carried out with the help of specialized software «KIMOs» of «Klingelnbеrg» company Robotic welding complex of «Yaskawa Nordik» company for welding of front suspension module parts 5 machining units of «Mazak» company for machining of suspension components E-coating line of IMEL spa (Italy) 5
Stamped steel wheels Stamped wheels One of the largest facilities producing wheel in the RF Wheels for local OEMs: Passenger car wheels (Ø13"-17.5"); LCV wheels (Ø16-18); Medium truck wheels (Ø18"-20") In-house tooling production Capacities: 1 500 thou. wheels p.a. Complete process cycle on one production site. Equipment: Stamping Schuler automatic multiposition press Rim welding and rolling Kieserling automatic line Wheels assembly and welding Danieli Automated painting line 6
Body stamping and armature Stamped parts Strain members of body (cross-members, struts, guiding profiles, side-members, base elements, supports etc.) Front parts of vehicle (roof, jacket, door panels, wings) Stamped and welded components of assemblies and automobile modules (basic structure of steering wheels, seat frame, dash panel frames, fuel tanks, suspension elements etc.) 250 thou. tons of stamped parts per year 1330 part names Parts of fuel tanks and welding of fuel tanks, stamping of underbody panels for vans and buses 420 items 10 Komatsu automatic lines with tonnage from 500 to 2500 t. Getz, Erfurt, Voronezh presses with tonnage from 250 to 6300 t. Chaika line for inner panel production, 5 presses Various equipment for assembling and welding 7
Frame and fuel system Fuel system 18 modifications of fuel tanks out of galvanized metal for the whole range of GAZ vehicles Frame Production of frames for GAZelle, Sobol and middle trucks. Possibility to carry out a complete production technological cycle: from blanking, welding and painting of finished parts. Capacities: Passenger cars 240 thou. pcs. p.a. LCV 240 thou. pcs. p.a. Medium trucks 200 thou. pcs. p.a. Possibility to carry out a complete production technological cycle presses ZIL allow to stamp parts up to 8 meters long state-of-the-art painting complex Capacities: 200 thou. pcs. p.a. 8
Forgings and leaf springs Forgings Leaf springs One of the largest forging in the RF 1 200 items of forged blanks produced from constructional and alloyed steels, D1, D16 and aluminum alloys АК6 The production has a complete die forging technological cycle (including heat treatment, straightening, coining and scale removal). Blanks for die forging are heated in induction gas and electric furnaces, as well as by applying direct resistance heating. In the heat treatment shop of the Forging Production the forged products undergo normalization, thermal improvement and isothermal annealing. Leaf springs for passenger cars and trucks The production has a complete process cycle starting from receiving and cutting metal to size to delivery of finished painted leaf springs to the assembly lines Automatic spring plate cutting complex Universal pressing and heat treatment equipment Unique automatic lines for manufacturing of few-plate leaf springs Paint spray booth Capacities: 40 thou. tons per year Equipment: Crank hot-forming presses with tonnage ranging from 630 to 6300 t. Horizontal forging machines with tonnage from 250 to 2000 t. Pneumatic die drop hammers with driver assemblies weighing 1000 kg. Automatic line for stamping large parts (based on forging hot stamping press with tonnage of 12500 t.) HATEBUR AMP-70 automatic stamping press with tonnage of 1500 t. AUMUCO automatic lines with tonnage of 3150 t. Clamping machines for manufacture of steering wheel shaft and tie rods Automatic transverse v-shaped rolling lines WRL10025TN-1, 40 t. Capacities: 110 thou. t/year 9
Grey and ductile iron castings Iron Castings One of the largest plants producing cast-iron castings Foundry products are castings of different complexities from grey, ductile, alloyed cast-iron and various grades of steel. The weight of the automotive castings varies from 0,01 to 100 kg with overall dimensions not exceeding 1000х1200х250 mm., and that of castings for repair purposes and die manufacture castings up to 12 tons. Typical grey cast-iron castings: brake drums, brake discs, fly-wheels, various box-type castings, clutch discs, cylinder blocks, cylinder heads. Parts for automotive axles, suspension, brake system as well as brackets, crank-shafts etc are manufactured from ductile iron. Equipment to make cores for cold-box and hot-box processes Induction melting and duplex process Automatic transportation of ductile iron to the line Production: 108 thou. tons per annum Capacities: 134 thou. tons per annum 10
Aluminum and other non-ferrous castings Non-ferrous casting Wide range of produced castings ( from 0,01 kg up to 50 kg) low pressure, high pressure, counter-gravity, gravity die-casting as well as sand core casting are used to manufacture castings from aluminum (АК9ч, АК12М2, AlSi9Cu3), zinc (ЦА4М10 etc.) and copper (ЛЦ40Сд etc.) alloys. Non-ferrous Casting Production Unit of GAZ OJSC possesses a wide range of equipment of globally known manufacturers such as Litostroy (Slovenia), INDRAPRESS, ITALLPRESSE (Italy) and BUEHLER (Germany) Capacities: 14.2 thou. tons of castings per annum. 11
Dies and press molds Dies and Press-Molds The largest plant in RF manufacturing specialized tooling (dies and molds) Cold sheet-metal stamping dies used for molding, trimming, bending, straightening as well as templates Press-molds: - Press-molds for plastic and foamed urethane parts as well as blow molds and gravity dies - Press-molds for industrial rubber and asbestos articles - Powder metallurgy press-molds High speed milling centers (Dynamil, FIDIA, Mikron) High-precision electroerosion CNC machines Mitsubishi, Agietron, Robofil 5-axes milling centers MEKOF Simulation and design are supported by modern CAD, CATIA V 5 and AUTOCAD systems. CAM-systems Power SHAPE (Delcam), Power MILL (Delcam), Work NCand ТЕХТРАН are used to develop manager programs for CNC machines. Hydro-elastic stamping system QUINTUS Flexform Press type QFC 1.8 x 3.6-1000 12
JV Bosal-GAZ Description Manufacturing of high-quality exhaust system components for OEM enterprises JV Bosal-GAZ JV founders 1. Bosal Group (Bosal Nederland B.V.) 2. GAZ OJSC Revenue (mio rub.) Product Potential customers R&D Technology Area Capacity Personnel Exhaust system, which meets Euro-4 requirements (hot end: catalytic converter, particulate filter; cold end: muffler, resonator, pipes) GAZ Group (Automotive plant GAZ), VW Contract assembly (GM, Daimler), Ford-Sollers, UAZ, Mitsubishi, other GAZ Group enterprises In the course of new products development JV Bosal-GAZ can attract competencies of Engineering Center Rosal Research, located in Belgium (120 engineers and technical specialists, wide technical and testing capabilities) Hot End: state-of-the-art high-performance line, which allows to manufacture products using stuffing process Cold End: welding automatic machines Tubes: tube bending using CNC machines 4 575 sq.m. (production site of GAZ OJSC Nizhniy Novgorod) 570 thou. systems/year 110 people 14 13
JV Bulten-GAZ Description Manufacturing of fasteners for OEMs. SOP the IV quarter of 2014 JV founders Product JV with Bulten for manufacturing of fasteners fasteners (nuts, bolts, screws, studs, pins, etc.) 1. Bulten AB 2. GAZ OJSC Potential customers GAZ Group, Takata Ford, VW, Renault, AvtoVAZ, Nissan, contractual assembly (VW, GM, Mercedes Sprinter) R&D Bulten s competence, UC LLC (GAZ Group) Bulten-Rus products, thou. t. Technology Space - Cold heading on high-performance automatic machines of foreign manufacturer (Sacma, Nedshroef Herentals, National Machineri, Kieserling) - heat treatment - machining and various finishing of fastener parts - coating Collini services - preliminary application of thread lock compound on fastener - Bonek (Henkel) services 13 685 sq. m. (facility of GAZ OJSC in Nizhniy Novgorod) 7,3 8,4 0,7 9,0 0,8 9,6 0,8 10,3 0,8 Capacity Personnel 10 000 tons 117 people 0,7 5,0 0,5 4,6 5,6 6,1 6,6 7,3 2,0 0,1 0,6 1,3 2,7 1,8 1,9 2,0 2,1 2,2 2,3 2013 2014 2015 2016 2017 2018 2019 2020 Current GAZ product mix OEM parts Resale 14
Plans for JV creation projects Direction Goal Partner Plan Wheels Forging Production Aluminum casting Platform Leaf springs Dash panel frames 16 Organization of high technology production with less investment inputs and capable to produce up to 4 mln. wheels a year Strengthening of competitive positions by attracting the Partner s competencies Supply of the products to global players Setting-up of a competitive JV obtaining up-to-date engineering competencies and forgings production technologies, on the basis of the operating GAZ facilities in Nizhny Novgorod Organization of high technology production with less investment inputs Strengthening of competitive positions by attracting the Partner s competencies Increase of the production volumes, supply of products to global OEM and OES companies located in Russia Setting-up of a JV for production of platforms on the basis of the operating GAZ facilities Raising the technology level and improving the products quality by attracting the partner s competencies Setting-up of a JV for leaf springs production on the basis of the operating GAZ facilities (including creation of technologies to be used for new products designed for vehicles of Next family) Supply of products to global players Setting-up of a JV for production of dash panel frames for GAZ Group, VW, Skoda, Daimler vehicles with capacity of 150 thou. sets a year Magnetto Wheels 2014 : Forges de Courselles, OMS, Hammerwerk Partner is not defined Scattolini Partner is not defined Matador Preparation of the project Business plan and the JVA Approval of the project at GAZ Board Meeting 2015 - Signing of the JVA, implementation of the project 2016 - SOP Development of the project concept Conducting of negotiations with Partners Preparation of the JV project Search for potential partner Conducting of negotiations and formation of the project concept Preparation of the JV project Formation of the project concept Conducting of negotiations with the Partner Preparation of the JV project Search for potential partner Conducting of negotiations and formation of the project concept Preparation of the JV project Formation of the project concept Conducting of negotiations with the Partner Preparation of the JV project
THANK YOU FOR ATTENTION 603004, Nizhny Novgorod, Lenin ave., 88 phone. (831) 299 09 90, fax: (831) 290 81 89 Epshteyn Kirill Director of Autocomponents Division e-mail: EpshteynKK@gaz.ru Alexey Zaytsev Director for Development, Autocomponents Division e-mail: ZaytsevAL@gaz.ru 15