ITB NEWS December 2012

The ITB Group, Ltd. Novi, Michigan, USA

+1(248)380-6310

www.itbgroup.com

Consulting assignments: Ms. Mitra O’Malley Managing Director momalley1@itbgroup.com Dr. Joel Kopinsky Managing Director jkopinsky@itbgroup.com Conference activities: Mr. Bryan Eldredge Program Manager beldredge@itbgroup.com

OEM Levers for Meeting Fuel Consumption Targets

Powertrain

• Downsizing—direct injection and boosting

• Improved combustion • Variable valve systems and

cam phasing • Friction reduction • Cylinder-on-demand • Cooled EGR • Start/stop • Improved gear ratios • Dual-clutch transmission • Advanced thermal manage-

ment • Exhaust energy recovery • Electrification

Overall Vehicle • Aerodynamic improvements • Mass reduction • Improved cabin conditioning

Planning • Fleet planning including foot-

print distribution • Maximize use of off-cycle cred-

its • Enhanced credits through elec-

trification

The ITB Group Continues Commitment to Carbon Dioxide Reduction

Our analysis shows that it is no longer enough to say that global warming will increase the likelihood of extreme weather and to repeat the caveat that no individual weather event can be directly linked to climate change. To the contrary, our analysis shows that, for the extreme hot weather of the recent past, there is virtually no explanation other than climate change. The deadly European heat wave of 2003, the fiery Russian heat wave of 2010 and catastrophic droughts in Texas and Oklahoma last year can each be attributed to climate change. And once the data are gathered in a few weeks’ time, it’s likely that the same will be true for the extremely hot summer the United States is suffering through right now.

James Hansen, Washington Post, Summer 2012

The monumental efforts by the OEMs to meet future legislation for CO2 emis-sions have invigorated The ITB Group’s initiatives related to sustainable trans-portation. Examples of future CO2 legislation in-cludes the 130 g/km target for European vehicles by 2015 and subsequent 95 g/km target for 2020.

The US has introduced related requirements for fuel consumption and CO2 emissions that fall into categories for the years 2012-2016 followed by 2017-2025. The new tar-

gets represent weighted fleet averages by mass in Europe and footprint in the US. The current status of the European fleet com-pared with the legislated targets is shown in the diagram below.

ITB’s initiatives related to CO2 reduction include:

• Ongoing consulting assign-ments evaluating new tech-nologies that help vehicles meet the new legislation. This often requires detailed interpretation of the specific legislative requirements. In other words, ITB helps its clients identify opportunities

buried within the legislation.

• ITB has completed a num-ber of multiclient reports that relate to the reduction of CO2 including reports on engine air and cooling systems and vehicle mass reduction.

• A number of ITB’s confer-ences emphasise technical developments that are enabling the OEMs to re-duce CO2 emissions from their vehicles.

• Facilitating M & A and technology licensing agree-ments that often relate to future growth resulting from the new legislation.

Source: Transport & Environment and The ITB Group, Ltd.

Cockpit, Consoles and Door Panel Developments

Conference News Page 2 The ITB Group, Ltd.

The cockpit is where the consumer comes into direct interaction with the vehicle. Key to this experience is the hu-man-machine-interface (HMI) strategy developed by the OEM. ITB has been providing expert assistance to suppli-ers and OEMs with an emphasis on the center stack of the cockpit. Recently ITB has expanded its efforts in this area with the development of a benchmarking service that will:

ITB completes multiclient reports that include cockpits, consoles and door panels that evaluate evolving styles, designs, materials and processes together with the impacts of new regulations. Examples include:

• Trends defining styling, architectures, surfaces and levels of electronic integration

• Identification of new material and processes including for decoration

• Evaluation of structural changes in the supply chain

ITB’s most recent automotive cockpit, console and door panel report is scheduled for publication in December 2012.

• Identify and benchmark leading center stacks in the marketplace • Uncover groups of center stacks that best represent the breadth of

center stack technology • Estimate the bill of material costs

• Identify best-in-world value engineering concepts • Develop Implementation Ready (IR) design & process technologies • Show concept implementation in teardown center stack assemblies • List risks & opportunities to take IR concept to Application Ready

Energy Storage Systems In March, 2013, ITB will host its 14th annual Energy Storage Systems, formerly Fuel Systems, conference. This must attend event for many of the world’s fuel system professionals a l lows

suppliers to network with their customers and discuss their latest product innovations. Bill Kozyra, Chairman, CEO and President of TI Automo-tive, will deliver the key-note presentation for the event. ITB is currently preparing to host its first Fuel Sys-tem conference in India in late September. This will be followed by ITB’s 7th annual Shanghai Fuel System conference. ITB’s Asian events have proven to be a valuable method for both the OEMs and their suppliers to network and enhance their know-ledgebase as the industry evolves globally. Mass Reduction Strategies ITB’s 4th conference on vehicle mass reduction will focus primarily on non-powertrain applications

and how these can con-tribute to reducing mass. Key developments in composite technologies, metallic products and joining technologies will be highlighted at the confer-ence. Air Induction and Cooling Systems Engine air induction, cooling and exhaust gas recirculation systems can bring about significant improvements in engine efficiency and emiss ions reduction. ITB’s June conference will focus on the impor-tant system and component design evolutions in this area together with related develop-ments in high temperature resis-tant thermoplastic materials.

Automotive Interiors In October, ITB will host interior conferences in both North America and China. ITB’s 2012 exclu-sive US event was com-prised of equal numbers of participants from OEMs, component and material suppliers. Themes covered ranged from surfaces, processes, control panels including vehicle apps, packaging and architectures.

ITB’s 2013 Automotive Conferences

Detroit, Michigan, USA Energy Storage Systems March 6 & 7 Mass Reduction Strategies May 2 Engine Air & Cooling Systems June 6 Cockpit Systems October 10

Shanghai, China Interiors October 30 Fuel Systems October 31

India Fuel Systems Late September

December 2012 Page 3

Fuel System Developments The automotive fuel system market has undergone significant develop-ments as a result of technical, legislative, supply and market drivers that include:

• Regulations such as California’s LEV III and Europe’s Euro VI • Changing fuels including increased use of ethanol and biodiesel • Special demands of plug-in hybrids and turbocharged gasoline engines that

provide limited canister purge opportunities • Ongoing structural changes to the supply base • The disruption to the supply of polyamide 12, an important material for a

number of extruded and injection molded fuel system components as a result of the fire at Evonik’s CDT monomer production facility in Germany

Evolution of Plastic Fuel

Tanks

Engine Air and Cooling Systems Help Improve Engine Efficiency Efforts to meet future legislated emission requirements including those for CO2 are leading to consid-erable innovation for improved powertrain performance. Leading these efforts is of course, vehicle electrification in its various forms for mild, full and plug-in hybrids and battery electric vehicles. Internal combustion engines have also been making significant strides in improv-ing efficiency, especially through downsizing efforts. Such approaches usually rely on boosting together with the use of direct fuel injection.

There are a number of strategies pursued by the OEMs that include design changes to engine air induc-tion systems, high and/or low pres-sure exhaust gas recirculation (EGR) and cooling architectures together with suitable control strategies. The accompanying exhibit shows the myriad of technological offerings open to the automotive OEMs for realizing improvements in combus-tion efficiency through modifications to air induction, cooling, boosting and EGR systems. The pressure

boosting of engine intake air is a key factor behind the success of down-sized engines for improved fuel economy. This has placed new requirements on air induction and cooling systems as a result of the need to incorporate and cool charged air. Past cooling systems have focused on minimizing component costs while fulfilling non-optimized engine requirements. Investments in ad-vanced thermal management tech-nologies offer significant perform-ance improvements such as mini-mizing coolant flow to the engine during warm-up but optimizing coolant flow during warm engine operation so as to minimize friction and maximize engine thermody-namic efficiency. ITB has completed a 530 page report that provides an in-depth analysis of business, legislative and technical developments impacting the automotive engine air, EGR and cooling market. In addition, the report features a chapter on engi-neering thermoplastic developments due to the significant role they play in enabling the success of today’s air induction and cooling systems.

In the summer of 2012, ITB completed its eleventh update report on the technical developments and business dynamics in the automotive fuel systems industry. The impact of the above drivers on the market were evaluated in this report together with numerous other technical and business developments.

Source: The ITB Group, Ltd.

Source: The ITB Group, Ltd.

Realizing Economic Value from Vehicle Mass Reduction

Page 4 The ITB Group

The ITB Group, Ltd. 39555 Orchard Hill Place Suite 225 Novi, MI 48375 USA Phone: +1(248)380-6310 Email: email@itbgroup.com www.itbgroup.com Asia • Europe • North America

Source: The ITB Group, Ltd.

Risk and Reward for a Vehicle

Cross-Car Beam

Reducing vehicle mass has been identi-fied as a significant factor in enabling the OEMs to meet future fleet targets for fuel consumption and CO2 emissions. A wide range of materials, processes and joining technologies that offer the potential for significant reduction in vehicle mass are being developed and evaluated. It is no surprise that the body-in-white is one of the areas receiving the most emphasis by the OEMs.

Some of the materials in addition to advanced steels receiving consideration as materials for body-in-white and other vehicle structural components include:

• Laminated steel structures that integrate structural and acoustic functions

• Tailored products including composite tapes, tailor-welded blanks and coils

• Fiber composites that not only offer mass benefits but also NVH and mass decompounding

• Aluminum, whose characteristics are well under-stood, is showing significant growth

Understanding the value of mass reduction alternatives is not as simple as just calculating investment, piece cost and mass ratios. There are additional hard and soft valuation and risk factors which must be considered.

ITB has developed an analytical tool for evaluating the hard and soft customer values that may include fuel savings, CO2 reduction and comparative vehicle per-formance. In addition, the tool considers subjective risks such as technology change, engineering requirements, limited resources and performance requirements such as crashworthiness associated with making changes to reduce mass. An overview example of the results of ITB’s analysis is shown in the graph above.

The total value proposition of mass reduction may be magnified when opportunities are considered in a complete vehicular context. Changes should not be considered in isolation, but across platforms and over time. There should be a constant evolution toward more idealized systems and improved customer impact.

ITB will be further developing its analytical tool for use by the automotive industry so as to help better guide its efforts and overcome the obstacles faced when attempt-ing to implement seemingly costly material options.

In December 2012, ITB completed a new 485 page report that evaluates the OEM strategies, legislation, emerging technologies and apparent economic benefits of vehicle mass reduction. Included within this report is a discussion of the analytical tool developed by ITB to use in evaluating various mass reduction concepts.

Ms. Mitra O’Malley Managing Director M.S. Plastics Engineering Mass Reduction, HMI

Dr. Joel Kopinsky Managing Director Ph.D. Chemical Engineering M.B.A. (Finance) Energy Storage, Emissions