GKN Driveline
CVJ Systems
AWD Systems
Trans Axle Solutions
eDrive Systems GKN at a glance
GKN Driveline GKN Powder GKN Aerospace GKN Land Metallurgy Systems
World leading supplier World leader in the Supplier to the global Supplier to the global of automotive driveline manufacture of aviation industry agricultural, systems & solutions sintered components Leader in the construction, mining and other industrial Focussed on solutions Manufactures manufacture of highly markets that create weight, precision automotive, complex composite space and fuel savings industrial and aero structures and Innovation within renewable energy and Committed to innovation consumer products engine products mass transit solutions Largest powder Developer of fuel producer in North efficient solutions to Global aftermarket distribution and service America lower emissions
2 GKN Driveline Europa
3 A Tier 1 Supplier to the major OE manufacturers in Automotive, Aerospace and Land Systems markets
Global engineering group Sales of £7.4 billion in 2014 GKN Aerospace A leading first tier supplier to the More than 50,000 people in more than 30 countries global aerospace industry.
GKN Driveline 2014 - Sales by division A world leading supplier of Other automotive driveline systems (1.5%) and solutions. Land Systems £94m (10.5%) £776m
GKN Powder Metallurgy One of the world’s largest manufacturers of metal powder Aerospace Driveline and sintered components. (30%) (46%) £2,226m £3,444m
GKN Land Systems A leading supplier of engineered Powder Metallurgy power management products, (12%) systems and services. £916m
All group financial data in this document relates to 2014 unless otherwise stated. Sales figures are presented on a management basis
4 Our strategy
Four strong Five strategic Creating long-term divisions objectives shareholder value
Lead in chosen Growth target: markets Above market Growth
Leverage global footprint
Technology driving margin Margin BUSINESS ROIC PERFORMANCE Group target: Target: 20% Operational 8-10% excellence
Cash Flow Sustain above Increasing cash flow, market growth EPS and dividends
5 GKN Driveline – at a glance
26,500 employees GKN Driveline is a world leading supplier of automotive driveline systems and solutions. As a global business serving the leading 46 manufacturing vehicle manufacturers, GKN Driveline develops, builds and supplies locations an extensive range of automotive driveline products and systems – 22 countries for use in the smallest ultra low-cost car to the most sophisticated premium vehicle demanding the most complex driving dynamics. 2014 Sales: £3.44bn
GKN Driveline GKN Driveline Sales by product 2014 Sales by customer 2014
Other 24% VW CVJ systems 15% Fiat Mitsubishi Chrysler AWD & eDrive 4% 11% Toyota Systems Group 5%
Other BMW Group 6% Ford 10% Tata Group 6% Renault GM Group Nissan 9% 10%
6 Driveline – Global footprint
U.K. France Sweden Poland Russia Spain South Germany United Italy Korea Slovenia Japan States China Turkey India Taiwan Mexico Thailand
GKN Driveline Malaysia Colombia Sales by region 2014 Singapore 26% Manufacturing plant Brazil Rest of 38% Australia world Europe Joint Venture
Corporate office / Engineering centre 36% Americas
7 Strategy - market drivers & trends Legislation and economy Global trends
Lightweight Mega platforms Efficiency − 75% of light vehicles based on mega-platforms Increasing move to electrification Small and medium platforms experience greatest growth Growing popularity of SUVs and AWD Tightening of CO2 and fuel economy targets
“Common platform” VW MQB Mega-platform 9 million vehicles
8 GKN Driveline – product segments
CVJ Systems AWD Systems Trans Axle Solutions eDrive Systems
CV Joints Propshafts Differentials eAxles Sideshafts Transfer Units Limited Slip & eTransmissions AWD Couplings Locking Differentials eMotors Disconnects Final Drive Units
9 A complete driveline solution
Leadership in all major product lines
10 GKN Driveline – CVJ Systems
efficient thinking Fuel saving technology Maximised performance
the technology leader in CVJ sideshafts countertrack™ CVJ Ballspline system weight, space and fuel savings smallest maximise off-road angle & movement lightest Reduce NVH improved efficiency most efficient solutions provider most extensive range of CVJs widest global footprint manufacturing CVJs in 20 countries
High performing, economic solutions Innovative shaft solutions
Twinball (ST) joint with Face Spline Sideshaft for performance vehicles 50% higher torque transfer Most compact shaft for AWD rear 54 degree articulation – tightest turning sideshafts (hang-on solutions) on the reduced assembly time & backlash market Compact and light-weight design
11 GKN Driveline – AWD Systems
dynamic thinking Reduces everything but performance AWD Disconnect System
the global leader in efficient all-wheel DTF propshaft interface Power Transfer / Rear Drive Unit drive systems reduces weight seamless engagement to AWD mode reduces assembly time very low drag torque unique capability to develop and reduces packaging space PTU with DTF propshaft interface manufacture full AWD Systems reduces system costs fuel consumption benefit world-class engineering over many years optimised components through full system understanding
Premium AWD Disconnect System High performance coupling
Power Transfer Unit / TWINSTER® EMCD® seamless engagement to AWD mode electric or hydraulic actuation no compromise all wheel drive low drag torque improved efficiency Optimised connection methods fuel consumption benefit
12 GKN AWD Systems
Introducing highly efficient, light weight AWD Disconnect Systems
Land Rover Evoque Fiat B SUV
5% fuel saving / 3-5% fuel saving /
CO2 reduction CO2 reduction High performance AWD AWD System with System with Twinster® ETM® disconnect
disconnect
13 GKN Driveline – Trans Axle Solutions
unlimited thinking Global supply Improved dynamic performance
a leader in conventional and controlled Open Differential Electronic Torque Manager (ETM®) differentials for transmissions and smaller packaging maximum traction axles weight saving maximum stability globally available manufacturing in all regions of the world full product range established and experienced player
Adaptable sophisticated technology Off-road expert
Electronic Torque Vectoring Electronic Locking Differential controlled fast cornering for premium cars fast locking rear axle for extreme off-road conditions
14 GKN Driveline – eDrive Systems
Electrified thinking Hybrid with improved performance Economies of scale
a pioneer in advanced electric and eAxle System eTransmission Family Approach hybrid drivelines first two-speed eAxle on the market compact improved EV and hybrid drive mode ultra quiet systems leadership capability fun to drive choice of interfaces & gear ratio standard product range More than 250,000 vehicles on the road eTransmissions success in each major automotive region broader range of motors
Proven technology Dynamic partnership
Multimode eTransmission Axial Flux Motor first Multimode on the market easy integration into hybrid and electric high efficiency, lightweight, compact drivetrains total control of fuel economy class-leading torque and power density seamless switching between modes wide range of motors available
15 GKN eDrive Systems
Building a leading position in the eDrive component and systems market
Electric Axles Electric Transmissions Axial flux motors
Key developments: Launches: Launches: - Design for manufacture PSA Hybrid 4 MMC Outlander PHEV - Lower rare earth content Citroen C5 Fiat 500EV re-enforced - Add smaller size Porsche Spyder 918 B9 Berlingo EV - Investigate induction motor BMW i8 - Explore use of sinter metal composites for stator
16 GKN – technology enabling the future
17 17 AWD Systems - global manufacturing (except Propshafts)
Asia Pacific Americas Europe
GKN Driveline Nagoya
GKN Driveline Bowling Green GKN Driveline Köping
GKN Driveline Tochigi
GKN Driveline Newton GKN Driveline Bruneck
GKN Driveline Shanghai
18 Growing demand for AWD
Consumers like AWD
− Safety, assured driving and performance
− But want acceptable fuel economy and CO2 OEMs like AWD
− Improves vehicle performance and image
− Sellable feature with content and margin
− Smaller model migration
Traditional Front-wheel All-wheel drive drive
Source: IHS Automotive LV forecast April. 2013, GKN analysis.
19 Technology leadership in AWD
The challenge of tougher legislation for emissions and fuel efficiency
2015 2020 2025 EU Legislation 130gCO2/km 95gCO2/km 75gCO2/km ?
GKN Driveline’s technology response
Today’s AWD Optimised AWD Disconnect AWD Hybrid/electric AWD
Fuel saving / CO2 reduction < 1.5% 2% to 5% 20% - 40%
GKN can influence market technology uptake – systems capability important
20 GKN Driveline in Sweden
Wintertest facility in Arjeplog
Production facility and application engineering centre in Köping
21 GKN Driveline Köping 2014
Turnover 291m €
934 employees
70,000 m2 floor space
Main customers − Volvo Cars, JLR, FIAT, BMW, Renault/Dacia, Audi, Porsche, Lamborghini
Production PTU/RDU 632.000 Gear set 995.000 Wheel units 94.000
22
Overall Business
Volvo XC90 / XC60 / V70 / Mini Countryman XC70 / S80 PTU PTU + RDU
Discovery Sport Renault Dacia Gear Sets / PTU + RDU ABB Robot Gear Sets
Porsche / Lamborghini / Audi New product FDU + coupler Disconnect system PTU + RDU
FIAT Disconnect System PTU + RDU
23 Köping plant
AWD Manufacturing Ring and Pinion, Gleason ground Heat treatment Aluminum housings Welding (EB, MAG, Laser) Assembly End of line testing Shafts, differentials Transmissions components Chassis: Knuckle production, wheel end assembly High automation
24 25 26 27 28 s
29 History of GKN Driveline Köping
Establishment AB Volvo Acquired by Köping starts GETRAG All Production of of Köpings buys Köpings GKN - manufacture Wheel Drive AWD systems Mekaniska Mekaniska GKN Driveline of AWD JV founded for Land Rover Verkstad Verkstad systems Köping 1856 1942 1996 2004 2005 2011
1927 1965 2003 2004 2010 2013 Start of Start of Introduction Production of Production of Launch of Gearbox production of of 6 - speed AWD- systems for AWD units for TWINSTER® production Rear Axles in M66 all Volvo AWD Cars BMW (Mini) for Jaguar for Volvo Köping Gearbox Land Rover
30 Inside GKN Driveline Köping and some of our products
31 GKN Driveline Köping – All functions on site
Production Manufacturing Engineering Programme Management Engineering (incl. prototype shop) Supply Chain Management Purchasing Sales, Quality, Finance & HR
32 Our strengths in Köping
Design, simulation and testing on-site for a process driven development Gear technology on-site competence from design, simulation to production NVH competence from simulation, rig test to car validation Prototype resources for short lead time and flexibility Effective and customer focussed Launch Process all functions on-site for efficient industrialisation Advanced production processes for hypoid- and helical gears
33 Quality assessment
ISO 14001 – 1996 ISO/TS 16949 – 2004 JLRQ – 2011 OHSAS 18001 – 2006 Ford Q1 – 2006
34 Gear Manufacturing Capability
In house gear design, manufacturing, tool design/manuf. , assembly and final testing
Spiral bevel gear sets manufacturing (cap: 900’/year), Gleason syst. with dry cut. and gear grinding
Helical gear manufacturing (cap: 400’/year)
Complete manufacturing (from forgings to MTE testing)
Blade cutter grinding for optimized tool life
100% marking and part traceability for all important features.
35 Aluminum Machining Centres
12 High speed 4-axis Makino and dry cutting designed Ex-Cello machining centres
Extra “axis” angular heads for drilling, threading and milling
In process automatic washing
100% leakage testing
36 Multiple Welding Technology
Three different welding technologies for different application needs, with over 20 years experience - Laser welding (with and without filler wire) - Electron Beam welding (vacuum) - MAG welding
In house welding specialist competence
Non destructive testing; Automated Ultra sonic weld quality check
Laboratory frequent batch destructive testing
37 Heat & Surface Treatment
Case hardening / Phosphating
Three pusher furnaces and one batch furnace
Manganese phosphating line
CQI 9 and CQI 12 certified
CHD range of 0.4-1.6 mm
Laboratory
Chemistry and metallographic laboratory
Spectrometer analysis
Carbon sulphur analysis
Fully equipped microscopic range (stereo, optical and SEM/EDX)
Fully automatic micro hardness test equipment
38 Assembly Technology
Semi automated high volume assembly lines
Designed ergonomically to be operator friendly
Multi variants with quick change over
Material handling minimized through easy access of material
100% objective EOL testing of all important features - NVH - Transmission error
100% data tracking for traceability
39 Measuring and Control
Gear measuring in Zeiss, Klingelnberg and Gleason
CNC inspection frequently of flank form, tooth thickness and pitch
Automatic calculation of needed machine corrections
CMM inspection of both castings and machined housings and covers
Inspection and control of geometrical tolerances such as form and position
First piece- and frequent CNC inspection
40