The Product Realization Company

A full-service EMS provider since 1980

Plexus Mission Statement

“To provide a complete menu of value-added designand manufacturing services, from which our customers can choose, giving them a competitive advantage in time to market, technology, flexibilityand total cost.”

Plexus: A Strong Balance Sheet*

• Cash & short term investments - $103 million• Long-term debt - $27 million • Shareholder equity - $388 million• Total debt/equity ratio – 7% • Symbol (NASDAQ): PLXS

* As of December 31, 2002; dollars in millions

Plexus Management Values

• Be passionate on meeting customer’s needs• Open and direct communication• Ownership/empowerment• Focus factory, team environment• Continuous improvement• Extensive use of metrics• Attention to the fundamentals

Plexus Business Philosophy

• Focus on high technology, high reliability products• Full suite of value-added services with multiple

entry points for customer• Industry experience• Scalability• Emphasis on outstanding customer service• Product Realization

High-Tech, High Reliability Products

Edge Routing Switches

(Unisphere Networks)

Class II and III Medical Products

(GE Medical)

High-End Computing (Unisys)

Industrial Products (High reliability, redundant control)

Full Suite of Value-Added Services

• World-class design and test technologies

• New Product Introduction (NPI) Plus plays a key role in product and process optimization

• Higher level services accelerate time-to-market and strengthen strategic relationships

Engineering NPI Plus Testing Manufacturing Sustaining Services

Industry ExperienceFor technology-based, high-reliability products

Based on Q1 FY03 Sales

34%

5%12%

14%35%

Networking/DatacomMedicalIndustrial/CommercialComputingTransportation/Other

Networking/Datacom Segment

• Mix of established OEMs and well-funded emerging customers

• Technology building blocks speed up the product development curve

• Broad spectrum of Networking/Datacom applications includes:

Optical Switching Wireless InfrastructureEdge Routing Core SwitchingSONET Broadband, etc.

Scalable Business Model

• Each business unit is focused on optimizing services through unique channels

• Scalable platform for growth

• Integrated customer development drives customer service excellence

CustomerDevelopment Technology Group

EngineeringElectronic Assembly

Manufacturing

Customer Service Excellence• Won Technology Forecaster’s Overall Service Excellence Award

for Large EMS Company in 2001, 2002 and 2003.

• Earned total of Eleven Technology Forecasters Service Excellence Awards over last five years

• Won Medical Design Excellence Award 2001 and 2002, also a Supplier to a Winner in 2001

• Won Industrial Design Excellence Awards in 2001

• Plexus ranked 8th in the Forbes Platinum 400 listing in 2002

• Designer won Top Gun Hall of Fame Award at PCB Design West 2002

EngineeringBoulder, CONashua, NHNeenah, WIPortland, ORRaleigh, NCSan Diego, CASeattle, WALivingston, ScotlandTel Aviv, IsraelPenang, Malaysia

● ManufacturingAppleton, WIBoise, ID Boston, MAChicago, ILNeenah, WIRichmond, KYSan Jose, CASeattle, WA

Juarez, Mexico Kelso, Scotland Maldon, EnglandPenang, Malaysia Xiamen, China

■ FutureSouthern USEurope Asia

Global and Regional Product Realization

Outsourcing Provides Value

• OEMs average about a 15% reduction in total product costs through outsourcing (Booz Allen Hamilton, November 5, 2001)

• Outsourcing advantages include:– Provides economies of scale– Allows OEM to convert fixed costs to variable costs;

improve return on invested capital (ROIC)– Provides access to technology and intellectual property– Frees resources to focus on core competencies– Improves functional flexibility and scalability

Why Outsource to Plexus?

• Faster time-to-market for new products

• Company began offering manufacturing and engineering from its inception

• 350 product development engineers on staff

• Plexus pioneered the concept of Product Realization

• Technology building blocks

• Commitment to customer service

• Stable workforce

Plexus Engineering

Engineering

“Value through World-Class Engineering and Product Realization Services”

What Makes Plexus Unique?

Comprehensive Product Realization Services

Plexus’ Engineering capabilities position the company as the industry leader in Product Realization

Engineering Structure

PCB Development• Portland, OR

• Nashua, NH

• San Diego, CA

• Livingston, Scotland

• Tel Aviv, Israel

Product Development• Neenah, WI

• Raleigh, NC

• Boulder, CO

• Seattle, WA

Test Development• Neenah, WI

• Seattle, WA

Engineering

Resources and Experience

Over 350 degreed Development Engineers, Designers and Technologists

14%3%

23%

11%

7%

11%

11%5%

Verification/SustainingTestPCB DesignSignal IntegrityDigitalAnalog, Optical, RFSoftwareMechanical

Turnkey Product Development

Specialized Engineering Services

Electrical design, analysisand layout

Mechanical design & thermal analysis

Software

ASIC design

Test Development

World Class Test Solutions

• Built-In Self Tests

• Boundary Scan

• Flying Probe

• In-Circuit

• Functional

• X-Ray Laminography

• Dedicated custom test stations

• Environmental Stress Screening (ESS)

• Automated Optical Inspection (AOI)

• Aware Test (ICT and X-Ray)

• Combinations of above

Example of Success

Novoste Beta-CathTM

Radiation Delivery System

• Enhanced design and verifiedfor CE marking and CSA in 7 months

• From concept to preproduction in only 17 months

• Rigorous design controls support successful PMA filing

• Created multiple product versions

• Designed 4 custom circuit cards including motherboard and synchronizer

Plexus Manufacturing

Volume Manufacturing

“We are committed to providing integrated turnkey solutions utilizing industry-leading engineering

capability and leading-edge manufacturing technologies to support our customer’s time-to-

market requirements with a focus on quality, service, and flexibility.”

Value-added Manufacturing

• Over 20 years experience manufacturing high technology, high reliability equipment

• Global and regional manufacturing locations available to meet our customer’s unit cost and distribution requirements

• Utilize the Focus Factory concept to provide flexibility

• Highly qualified work force empowered to “own” the Focus Factory

• Plexus Technology Roadmaps ensure customer access to leading-edge manufacturing solutions

What Makes Plexus Manufacturing Unique?

• Materials Solutions• Processes• Advanced Manufacturing Solutions• Test Solutions• Quality• Focus Factory Methodology• Customer Teams• Mix• Volume

Materials Solutions

• Provide multiple material management models for customer’s unique requirements

• Distributor In-House Stores

• International Procurement Stores (IPOs)

• Bill of Material Obsolescence Software predicts component life cycle

• Component Engineering support• Proven cost improvement methods

ProcessesMaintain leading edge manufacturing processes to meetdiverse customer needs in appropriate industry segment• Surface mount technology

• Double Pass Reflow

• Pin-in-Paste (Intrusive Reflow)

• PTH Auto Insertion

• Conformal Coating

• Mechanical Assembly

• Backplane (Compliant Pin)

• Optical fiber splicing

• RF product assembly

Test Solutions

Comprehensive suite of test solutions include:

• Flying Probe Manufacturing Defect Analysis (MDA)

• ICT

• Functional Test

• X-Ray Laminography

• Aware Test (ICT and X-Ray combination)• Environmental Stress Screening

(ESS)

Design for Excellence (DFX)

• Our design and manufacturing experience has been incorporated into a set of DFX guidelines

• Results include higher yields and increased throughput

• Encompasses Design for Manufacturability (DFM), Design for Testability (DFT), and Design for Assembly (DFA)

Quality

• Plexus Quality system operates on Management by Metrics philosophy

• Key process steps are monitored based on

Defects per Million Opportunities (DPMO)

• Strong management commitment to continuous improvement through internal Six Sigma program (COBRA)

• Registrations include: ISO 9002, QS9002,

EN 46002, and FDA Class I, II, and III

• Quality data accessed by customers using a secure Plexus website

Focus Factory Environment

• Plexus will configure a Focus Factory to meet each customer’s unique needs in the areas of – Technology– Volume – Mix– Material flow - Pull, POU, IPS, CFM – Box build and configuration– Agency Requirements

• Benefits include:– Continuous improvement through dedicated personnel– Maximum flexibility– Adaptable to customer changes in product mix or

materials strategy– Accommodates rapidly changing customer needs

Lean Manufacturing

• Dynamic customer base requires manufacturing partner that is extremely flexible.

• Create a culture that is focused on reducing the amount of non-value add functions and substantially shorten the overall lead time that benefit both Plexus and its customers.

• For the customer, lean manufacturing drives:– Reduced lead time (time to market)– Lower overall product cost– Increased flexibility… frequency and reduce risk– Enhanced quality… product and procurement process

Customer Teams

• Dedicated cross-functional team• Empowered to manage their Focus Factory• Responsible for developing and maintaining

a successful relationship with the customer

Team Functions:– Strategic Customer Manager– Program Manager – Focus Factory Manager– Quality – Materials – Finance – Documentation Control– Administrative– Technical Support

Sustaining Services

…to complete the Product Realization mission

• Direct ship to end customer• Warranty and depot repair• Material obsolescence management• Product upgrades• Toll free phone support• Failure analysis• Warranty and service reports

Example of SuccessEthicon Endo-SurgeryMammotome®

Breast BiopsySystem

• Facilitated FDA approval of Class II device in 59 days

• Aggressive manufacturing for production goals

• Product to market in 18 months

• 2 full-custom in-circuit test fixtures

• 5 full-custom functional test fixtures

• Dedicated manufacturing and sustaining production support team

“When our Customers win, We win”