Geico’s Approach to Paintshop:

Innovation & Sustainability

AMS South America Conference
September 3rd, 2012
São Paulo

Fabrizio Mina, Executive Director Americas, Geico SpA

Index

Geico Taikisha Alliance

Geico in Latin America

Pardis Project: Geico
s Innovative Energy Saving Technologies

QOROS Project: Geico
s Most Innovative Plant

Focus on J-Jump Conveyor System

2
1st Year Anniversary - Geico & Taikisha Alliance

May 19 th 2011

Geico & Taikisha create a Global Alliance and

Geico becomes a member of Taikisha Group

3
Geico Taikisha Global Alliance – Commercial Guideline

Geico Taikisha Global Alliance will enhance both companies
ability to serve their customers around the world in
providing Turnkey Coating Systems for the vehicle industry, thorugh their 26 subsidiaries around the world.

Taikisha Headquarter
Tokyo, Japan
Geico Headquarter
Cinisello Balsamo, Milan, Italy

4
Geico Taikisha Global Alliance – Commercial Guidelines

The Alliance is enhanced by the complementary customer base served today by both companies.

(1 ) Geico will be in charge of the American (North, Centre, South), the European (including
Russia) and the Middle & Near Eastern vehicle manufacturers.

(2) Taikisha will be in charge of the Japanese and Korean car manufacturers.

(3) In India, China, and other countries in Asia & Africa,

Geico shall be in charge of all the vehicle manufacturers that have JV or licensing agreements with
point (1) above.

Taikisha, instead and with the same token, shall be in charge of those listed in point-2 above.

5
Geico Taikisha Global Alliance – Commercial Guidelines

The complementarity between the two companies applies also to the technical point of view.

Geico & Taikisha can share know-how and technologies:

Taikisha
s Counterflow, ILAS, Integrated Air Shield, etc..
Geico
s J-Jump, J-Flex Rotating System, Dryspin dry scrybber, etc..

Geico
s and Haden
s IP, patents, trademarks, and technologies remain of Geico
s property and
management.
Taikisha can use them for the Japanese and Korean vehicle manufactures.
Their development remains of Geico
s responsibiity.

Geico will have access to Taikisha
s Technologies, Suppliers Base, Engineering,

Manufacturing Units, and Offices globally.

6
Order Acquisition 2011 - Paint Division - Summary (US$) - Countries

Total Order Acquisition $ 1.041.000

350.000

 


300.000

250.000

200.000

150.000

100.000

50.000

0
China
Thailandia 2010
Japan
India
Brazil 2011
Europe
Nafta
Others
7
Geico & Taikisha Alliance

Over 4,000 Employees

U.S. $ 1.7 Billion Annual Sales

Present in more than 20 Locations Worldwide

, allGeicoproject
s Partner in Latin America

Above 800 Engineers & Specialists in Paint Finishing Business

World Class Manufacturing Facilities

Own Tecnologies; J-Flex, J-Jump, Dryspin, Hydrospin plus,

ILAS, Speedry, Automatic Application

Owners of HADEN Intellectual Properties,

Patents, and Trademarks

8
Index

Geico Taikisha Alliance

Geico in Latin America

Pardis Project: Geico
s Innovative Energy Saving Technologies

QOROS Project: Geico
s Most Innovative Plant

Focus on J-Jump Conveyor System

9
Geico Taikisha Alliance’s Offices in Latin America

Geico Brasil Ltda

Rua Francisco Rocha, 2113
CEP. 80710-540 Bigorrilho - Curitiba
Paranà - Brasil

Taikisha do Brasil Ltda.

Rua Maestro Cardim, 1293
CJ.102-10°Andar-bera Vista
Sao Paulo - Brasil

Falcare Equipamentos Industriasi Ltda

Member of allGeicoproject
Independent Lincenced Partner Company
Rua Arlindo Marchetti, 215
Bairro Santa María 09560-410
São Caetano do Sul – Brasil

10
Geico Taikisha Main Projects in Latin America

Complete Paint Shop Primer and top PT-ED Line

Sete Lagoas, Brazil
colour painting line
Porto Real, Brazil
Belo Horizonte, Brazil

Complete Paint Shop Complete Paint Shop

Uberlandia, Brazil
Uberlandia, Brazil
Sorocaba, Brazil
Cordoba, Argentina
Complete Paint Shop Zarate, Argentina
Sorocaba, Brazil
Somaré, Brazil
Sete Lagoas, Brazil
Belo Horizonte, Brazil
Porto Real, Brazil
Somarè, Brazil
Curitiba, Brazil
Complete Paint Shop
Campana, Argentina Curitiba, Brazil

Expansion PT-ED, Booths,

Complete Paint Shop Ovens
Cordoba, Argentina
Passenger Cars
Zarate, Argentina Campana, Argentina

11
Index

Geico Taikisha Alliance

Geico in Latin America

Pardis Project: Geico
s Innovative Energy Saving Technologies

QOROS Project: Geico
s Most Innovative Plant

Focus on J-Jump Conveyor System

12
Pardis Project: the Road Map

13
Year 2005

14
J-Flex

15
Air Recirculation

16
Dryspin

17
Nanotechnologies

18
3 Wet

19
Robots

20
Dryflex

21
Alternative Energies

22
Index

Geico Taikisha Alliance

Geico in Latin America

Pardis Project: Geico
s Innovative Energy Saving Technologies

QOROS Project: Geico
s Most Innovative Plant

Focus on J-Jump Conveyor System

23
 Production Strategy

Location Changshu, Jiangsu Province, China

Products “C” Class Family of Vehicles

Sedan phase 1
Notchback
SUV

Production volumes Phase I up to 250.000 units/year

Production rate Phase I 36 JPH NET

Working days 350days/year

24
 Painting System
The new Qoros painting system combines the latest application technologies in compact processes to achieve
world class quality with a critical eye towards environmental stewardship.

Topic Highlights on Paint shop

“Green”
  Lower carbon footprint through compressed processes

  Significantly less water usage
Initiatives


  Waterborne coatings (lower VOC emissions)

  High efficiency application technology

Quality
  Next generation topcoat process for improved visual

Leadership
appearance

  Precise Robotic application of coatings to assure consistency

  First ever J-Flex rotating conveyor system

Innovation


  Dry spray booth design (Uses NO water): Dryspin

  First to use the last innovative processes throughout entire
paint shop

25
500 kWh/unit: Lay-out
3 COAT – 1 BAKE

DRYSPIN
GEICO
S
DRY
SCRUBBER

NANOTECHNOLOGIES

SPEEDRY

J-FLEX
GEICO
S CONVEYOR
ROTATING SYSTEM

26
Plant: Energy Consumption

Project Benefits

Compact transport system 45 kWh/job

compact transport solutions J-Flex compared to traditional 13 kg CO2/job

Fixed consumption with

Flexible ITO variable production
Solutions fit for variable production in ITO 30 kWh/job
10 kgCO2/job

Multizone control in process ASUs 54 kWh/job

6 zones control and variable SP in function of external climatic
18 kg CO2/job
situation cascade from manual to automatic application zone

Global Energy Management

General knowledge
SW for monitorization of a paintshop consumptions

Cascade and recycle solutions in paint booths 30 kWh/job

cascade vs olutions from manual to automatic zones or recycle
10 kg CO2/job
in automatic zones

27
Plant: Energy Consumption

Project Benefits

DRYSPIN booth 50 kWh/job

Geico’s Dry scrubber 18 kg CO2/job

Low consumption ovens 10 kWh/job

Max of solutions for energy reduction in convention ovens 3 kg CO2/job

High efficiency motors 4 kWh/job

use of high efficiency motors 2,2 kg CO2/job

VFD (inverters) wide use 20 kWh/job

VFD tecnology anywhere a variable condition may happen 10 kg CO2/job

Air cascade in building 15 kWh/job

reduction of renewal air by mean of an optimization of building
5 kg CO2/job
sectorization

28
The J-Flex: Test @ Pardis Innovation Center

Speed adjustment

Locking device Dip & Rotate test

Simulation Test
29
J-Flex @ QOROS: Facts and Data

240 sqm SAVED 15 kWh/job SAVED

Pendulum J-Flex

Building occupancy

Energy Consumption

Cost of ownership

Movement flexibility

The best for any body

and process

30
Dryspin @ Pardis Innovation Center
Sliding floor Easy cleaning Dryjet Newty Filtration unit

Precoat ejectors, divided Complete with doors for manual

Retractable floor; divided Non-stick coatings for easy Easy to clean
into elementary operations and automatic system
into sections paint overspray easy removal conveyor type
components for exhaust powder extraction

How it works

31
Dryspin @ QOROS

Item Characteristics

Precoat Material Calcium Carbonate

Paint overspray to precoat ratio 1:3

Filter type KELLER Pro-Bran

Filtration efficiency > 99,9%

Dryspin length (total) 78 m

32
Dryspin @ QOROS: Facts and Data

Wet scrubber Dryspin

Water usage

Energy Consumption

Cost of ownership

Waste recovery

20,000 cu.m. water 100 kWh/job SAVED

saving per year

33
Index

Geico Taikisha Alliance

Geico in Latin America

Pardis Projects: Geico
s Innovative Energy Saving Technologies

QOROS Project: Geico
s Most Innovative Plant

Focus on J-Jump Conveyor System

34
The J-Jump Family

Main installations of J-Jump Conveyor System in the world:

Brazil - 2013

Brazil - 2012

SAIC China - 2009

India - 2009
35