Automobile Painting in the BRIC Countries - Quality at low Cost - Dr. Hans Schumacher, Dürr Systems GmbH

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1 Automobile Painting in the BRIC Countries - Quality at low Cost - Dr. Hans Schumacher, Dürr Systems GmbH Paris, June 11/12, 2009

2 Automobile Painting in BRIC Countries Quality at low Cost? Appropriate Quality + Low investment + low running costs Corrosion protection Appearance Colour palette/effects Quality constancy Reduced plant footprint Lean process Energy reduction Reduced material consumption Automation Low complexity equipment -2-

3 BRIC Countries: Emerging Markets? World Population 2008 (Mio) Non BRIC 3.906; 58% 42% of world population Highest population growth in Asia BRIC Brazil Russia 1.339; 20% China 1.166; 17% India 140; 2% Russia 199; 3% Brasil India Economy 2008 (GDP in Tril. USD) Economy Growth (% GDP) GDP [Tril. USD] Growth [% GDP] 69,5 16 China 22 % of world GDP Highest economical growth ,8 7,4 7,3 7,8 5,2 3,8 3,3 2 2,2 Brazil Russia India China World Source: CIA, The World Factbook -3-

4 BRIC Countries: Emerging Markets? Automobile Production in BRIC Countries (x 1000 vehicles) Brazil Russia India China 24 % of automobile production (2008) Production growth shifting to BRIC countries BRIC Brazil Russia India Highest growth expected in Russia, Latin America, China Mobility Development (Vehicles/1000 people) North America 600 Europe 500 Russia Latin America China India China -4-

5 BRIC Countries: Emerging Markets? BRIC Automobile Production in 2009 (current) Average changes compared to 2008 in % ,9 0,0 2,7 Brazil Russia India China Europe USA Brazil Russia India ,8-17,2-29,4 China Actual forecast in economical slowdown Strong negative growth in Europe and USA Still positive growth in China -5-

efficiency High reliability High safety standards High individuality Shift within the consumer

6 Vehicle Characteristics / Market Demands BRIC Countries Established Markets Robust Simple Low costs No need for individuality Reliable Low consumption New group of consumers High quality High efficiency High reliability High safety standards High individuality Shift within the consumer group Trend Trend Ultra low segment Luxury low cost Fair quality level Low cost segment Fair quality level -6-

7 Standard/Lean Paint Processes Standard PT/ED PR BC BC 1K CC Solventborne Standard PT/ED PR BC BC 1K/2K CC Waterborne Standard Lean PT/ED Solid Monocoat Tata PT/ED PR PT/ED PR PT/ED Characteristics Tight process window BC BC BC BC BC BC 1K CC 1K CC 2K CC 3wet Medium Solid 3wet High Solid Primerless Mazda, Kia, GM, Suzuki, Hyundai, Tata Ford Daimler, BMW, Mini, VW, PSA, Seat, Honda, Mitsubishi, Kia, Toyota, Daihatsu, Nissan Operation on limit Demand for automation -7-

Cost Effective Solutions (Process) Ecopaint RoDip Rotation Dipping

process window Optimized Downdraft in Spray Booth EcoDryScrubber 40

reduction Less energy High quality approx.

2 % Downdraft reduction by 10 to 20% Less Energy Higher TE approx.

8 Cost Effective Solutions (Process) Ecopaint RoDip Rotation Dipping PT/ED Topcoat Temp. & humidity control for max. process window Optimized Downdraft in Spray Booth EcoDryScrubber 40 C 29 C/68% 50% 60% 70% 80% 30 C Too wet Too dry 20 C 21 C/62% Space reduction Less energy High quality approx. 5 % Less Energy High Quality (constant paint evaporation) approx. 2 % Downdraft reduction by 10 to 20% Less Energy Higher TE approx. 2 % Space reduction Reduced air supply system Less energy approx. 3 % Basis: complete paintshop; figures exemplary -8-

9 Cost Effective Solutions (Paint Application) Exterior Painting Elevated Robots EcoRP E Interior Painting EcoRP E/L Dual Rail System System Modularity Low Complexity Linear Colour Changer EcoLCC Reduced footprint Less energy for ventilation approx. 2 % Reduced footprint Less energy for ventilation Full degrade mode possible approx. 2 % Simplified maintenance High Uptime approx. 3 % Low colour change loss (< 10 ml) For exterior and interior painting Simple technique approx. 2 % Basis: complete paintshop; figures exemplary -9-

paint duct No paint carryover possible Suited for exterior and interior painting System

carriage approx. 2 % Simplified maintenance High Uptime approx.

10 Cost Effective Solutions (Paint Application) Exterior Painting Elevated Robots EcoRP E Interior Painting EcoRP E/L Dual Rail System EcoLCC - Linear Color Changer Color changer without main paint duct No paint carryover possible Suited for exterior and interior painting System Modularity Low Complexity Linear Colour Changer EcoLCC Reduced footprint Less energy for ventilation Linear cylinder approx. 2 % Reduced footprint color strip Less energy for ventilation Full degrade mode possible docking carriage approx. 2 % Simplified maintenance High Uptime approx. 3 % Low colour change loss (< 10 ml) For exterior and interior painting Simple technique Color loss less than 10ml Color change time < 10s Simple technique approx. 2 % Basis: complete paintshop; figures exemplary -10-

11 Cost Effective Solutions (Paint Application) Atomizer with Integrated Colour Changer EcoBell2 ICC Bell/Bell Application EcoBell2 M Atomizer for Interior and Bumper Painting EcoBell2 HD High Performance Flexible Bell EcoBell2 HX Very low colour change loss (2 ml) Short colour change time (6 s) approx. 3 % High increase of TE (typical 35 %) Reduction of cleaning expenditure approx. 2 % High increase of TE (typical %) Reduction of cleaning expenditure approx. 2 % For exterior and interior painting with same Bell Full degrade functionality approx. 3 % Basis: complete paintshop; figures exemplary -11-

Cost Effective Solutions (Paint Application) Atomizer with Integrated Colour Changer EcoBell2 ICC Bell/Bell Application EcoBell2 M Atomizer for

loss (2 ml) Short colour change time (6 s) approx.

6 400 7 300 8 200 9 100 11 0 LL2 NL/min 0 100 200 300 400 500 600 600 600 600 600 Lenkluft 1 /2 NL/min approx.

(typical 15 25 %) 6 5Reduction of 4cleaning 3expenditure 2 1 0 200 250 300 350 400 450 500 550 600 650 700 750 800 approx.

12 Cost Effective Solutions (Paint Application) Atomizer with Integrated Colour Changer EcoBell2 ICC Bell/Bell Application EcoBell2 M Atomizer for Interior and Bumper Painting EcoBell2 HD EcoBell2 HX - High Performance Flexible Bell High Performance Flexibel Bell EcoBell2 HX Very low colour change loss (2 ml) Short colour change time (6 s) approx. 3 % SB50 mm 300 High increase of TE 250 (typical 35 %) 200 Reduction of 150 cleaning 100 expenditure 50 0 LL1 NL/min LL2 NL/min Lenkluft 1 /2 NL/min approx. 2 % Different applications with one Bell: exterior, interior, bumper Enables flexible zone sectioning and degrade mode 9 8 High increase of TE 7 (typical %) 6 5Reduction of 4cleaning 3expenditure approx. 2 % 8000 U/min 0 KV For exterior and LL1 LL2 S B50 interior N L/min painting NL/min mm with same Bell Full degrade functionality approx. 3 % Basis: complete paintshop; figures exemplary -12-

13 Automobile Painting in Latin America Ford Cuautitlan, Mexico Project Highlights 3wet high solid process (EcoBell2 HX) Elevated robots for exteriors, dual rail solution for interiors Full degrade mode for exteriors and interiors (lights out paintshop) -13-

14 Automobile Painting in BRIC Countries Ford São Bernardo do Campo, Brazil Project Highlights Elevated robots for exterior and interior application in the same zone/with the same robot Bell/Bell for BC1/BC2 (EcoBell2 M) -14-

15 Automobile Painting in BRIC Countries CAOA Anapolis, Brazil Project Highlights Elevated robots for bumper application Bell application with EcoBell2 HD for high TE Reduced complexity Primer Basecoat Clearcoat -15-

16 Automobile Painting in BRIC Countries VW Kaluga, Russia and Pune, India Project Highlights Two identical paintshops, Ecopaint RoDip for pretreatment and E-Coat First time Bell/Bell application within the VW Group (EcoBell2 M) EcoLCC colour changer Primer BC1/BC2 1K CC -16-

17 Automobile Painting in BRIC Countries Ford Chennai, India Project Highlights Lean Process (High solid 3wet) Robot application for Exteriors Bell/Bell application for BC1/BC2 (EcoBell2 M) 1K CC BC1/BC2 Primer Feather Duster -17-

Automobile Painting in BRIC Countries Tata Sanand,

for Nano luxury, Monocoat Line for Nano standard )

application for exterior areas Bell/Bell application

18 Automobile Painting in BRIC Countries Tata Sanand, India Project Highlights 2-Line-Concept (3wet Line for Nano luxury, Monocoat Line for Nano standard ) Ecopaint RoDip for pretreatment and E-Coat, Robot application for exterior areas Bell/Bell application for BC1/BC2 with EcoBell2 ICC Primer BC1/BC2 1K CC Solid -18-

Automobile Painting in BRIC Countries Mahindra

for pretreatment and E-Coat Elevated robots for

BC1/BC2 with EcoLCC colour changer and EcoBell2

19 Automobile Painting in BRIC Countries Mahindra Chakan, India Project Highlights Ecopaint RoDip for pretreatment and E-Coat Elevated robots for exterior application Bell/Bell application for BC1/BC2 with EcoLCC colour changer and EcoBell2 ICC for Primer and CC/Solid Primer Line Topcoat Line -19-

Automobile Painting in BRIC Countries JiangHuai

(waterborne, indirect charge) EcoBell2 ICC for

20 Automobile Painting in BRIC Countries JiangHuai Automobile Co., Hefei, China Project Highlights Elevated robots for exterior application Bell/Bell for BC1/BC2, (waterborne, indirect charge) EcoBell2 ICC for Primer (waterborne, indirect charge) CC/Solid (solventborne, direct charge) Primer Line Topcoat Line -20-

21 Automobile Painting in BRIC Countries SGM Norsom, Shenyang, China Project Highlights Ecopaint RoDip for Pretreatment and E-Coat Robots for exterior application Bell/Bell for BC1/BC2 (waterborne, indirect charge) Topcoat Line Primer Line -21-

22 Automobile Painting in Europe Audi, Brussels, Belgium Project Highlights Robots for exterior and interior application EcoBell2 HD for interior application (waterborne paint, no charge) EcoLCC colour changer Primer Line Topcoat Line -22-

23 Summary and Perspective BRIC and established markets are getting more and more equal Quality differentiation rather by painting processes, not by paint equipment Automation makes new lean paint processes more stable Quality at low costs necessary and possible for all markets and enabled by simple and most efficient paint equipment -23-

24 Thank you for Attention Questions?

Ecopaint Training TRAINING PROGRAM 2017

Ecopaint Training TRAINING PROGRAM 2017 www.durr.com TABLE OF TABLE OF CONTENTS CONTENTS 1 Electrical robot maintenance Electrical maintenance EcoRP6/7 F with EcoRC2... 4 Electrical maintenance EcoRP E/L