solvay engineered polymers
DESCRIPTION
TRANSCRIPT
Solvay Engineered Polymers
Company Overview
Solvay Engineered Polymers
The Company • an independent, wholly owned subsidiary of Solvay America, Inc. of Houston, Texas. The Solvay Group of chemical and pharmaceutical companies operates in more than 40 countries
• the largest North American Supplier of elastomer-modified thermoplastic olefins (TPOs) and other engineered polyolefin materials to the automotive industry
• a recognized leader in the automotive applications engineering for polyolefin materials
• materials used in a wide variety of interior, exterior, and underhood applications by the world’s largest OEMs
• Sales of $150-200 million, with continued rapid sales growth projected for the future
1200 Harmon RoadAuburn Hills
Michigan48326
Solvay Engineered Polymers
History 1976 Ciba-Geigy establishes TPO business:
• Ren-Plastics Division
1982 Business spun off in management buyout:
• Research Polymers International (RPI)
1986 RPI acquired by The Dexter Corporation:
• Dexter Plastics Division
1990 TPO business resources placed into joint venture formed between The Dexter Corporation and The Solvay Group:
• D & S Plastics International
1997 The Solvay Group obtains The Dexter Corporation’s share of the joint venture
• Solvay Engineered Polymers
Solvay Engineered Polymers
The Solvay Group• Founded in 1863
• 1997 sales of $8.4 billion
• 350 operating locations in 41 countries
• 35,400 employees worldwide
• Global chemicals and pharmaceuticals markets:
– Alkalis
– Peroxygens
– Plastics
– Materials processing
– Health industry
• 1997 Polypropylene Sales
– 742 Million Lbs.
• 1997 Polyethylene Sales
– 1.7 Billion Lbs.
• Headquarters in Brussels, Belgium
Solvay Engineered Polymers
Business Resources• Production Description:
TPO and engineered polyolefin materials
• Target Market:
Automotive OEMs and injection molders
• Manufacturing Capacity:
>225 million pounds per year, worldwide
• Employees worldwide: 325
• Current customers: 70
– Big 3 US carmakers: Daimler/Chrysler, Ford, GM
– North American transplants:
Honda, Mazda, VW, BMW
– Overseas OEMs:
Hyundai, BMW, Rover, Mercedes, Fiat
– Parts manufacturers/molders worldwide
Solvay Engineered Polymers
Market PositionNorth American Automotive
• Largest TPO supplier to North American automotive industry
• Major supplier to transplant operations
European Automotive• Current sales of airbag cover
materials• Production and development
programs at most major OEMs
Far East Automotive• Active presence in Japan, Korea,
Taiwan
Mytex
Solvay
SchulmanMontell
Other
CCT
North American automotive plastics market totals an estimated 2360 million pounds
TPO represents 9% of the plastics use -- an estimated 225 million pounds
Solvay Engineered Polymers
Worldwide FacilitiesAutomotive Applications Development Center
Auburn Hills, Michigan
Manufacturing and R & DGrand Prairie, Texas
Mansfield, Texas
Beerse, Belgium
Donjin, Korea
European Technical CenterBrussels, Belgium
North American Sales OfficesAuburn Hills, Michigan
Concord, Ontario
Union, Kentucky
Circleville, Ohio
Worldwide Sales OfficesChiba, Japan
Schorndorf, Germany
Paris, France
Milan, Italy
Coventry, United Kingdom
Solvay Engineered Polymers
Vision StatementSolvay Engineered Polymers will be recognized as the world’s leading supplier of engineered polyolefin materials to the automotive industry.
Mission Statement
Solvay Engineered Polymers is the development partner of choice in the automotive market for engineered polyolefin materials and applications technology. We are committed to continuously improving our product, services, and human resources in order to fully satisfy our internal and external customers’ needs and expectations. By providing innovative, timely and cost effective solutions to automotive industry needs, we will meet our objectives for growth in sales and earnings.
Solvay Engineered Polymers
Quality StatementAs employees of Solvay Engineered Polymers, we recognize that quality is a key strategic issue in the achievement of our business goals and objectives.
We are committed to the principle of continuous improvement in quality, productivity, cost, technology and delivery in order to provide our customers with world class quality products and services and in order to improve our internal efficiencies and operating results.
We will utilize cross-functional teams, statistical tools, advanced quality planning techniques, and clearly defined procedures and work instructions as the primary methodologies for achieving continuous improvement.
Every employee in our business is involved in this task, starting with members of the Lead Team.
Solvay Engineered Polymers
Solvay Eng. Polymers
New Automotive Applications
New Products
New Geographies
InteriorUnderhood
Europe
Mexico
TPVs
RTPO
Solvay Engineered PolymersFuture Growth
Solvay Engineered Polymers
Automotive Material Trends
Application 1990 2000
Bumper fascia RIM, PC/PBT, TPO, PBT TPO, RTPO, RIM
Air dam/valance TPO RTPO
Fender liner PP PP
Fenders PPO/Nylon, RIM, SMC,PBT/PET
TPO, PPO/Nylon, ABS/PC,PBT/PET
Grilles ABS, TPO, ABS/PC TPO, ABS, ABS/PC
Cowl vents SAN, ASA SAN, ASA, TPO
Mud flaps TPR, TPO, Ionomer TPR, TPO
Rockers TPO, TPR, RIM TPO
Claddings/moldings TPO, TPU, PVC, RIM TPO, TPU
Door panels ABS/PC, SMC ABS/PC, SMC, TPO
Exterior applications
Solvay Engineered Polymers
Application 1990 2000
IP substrate ABS/PC, Steel, SMA, PC ABS/PC, Steel, PP, SMA
IP cushion PU PU, PE
IP skin PVC/ABS PVC/ABS, TPO
IP upper PC blends TPO
Trim upper ABS, HIPP PP
Trim lower PP, TPO PP, TPO
Door trim PP, PE, PVC PP, PE
Airbag door TPO, RIM, TPE, TPR TPO, TPE, TPR
Interior applications
Automotive Material Trends
Solvay Engineered Polymers
Product Line Overview
• DEXFLEX
– Compounded TPOs (50-280 kpsi)
• FORTILENE
– Polypropylene resins from Solvay
• ONTEX
– Directly paintable TPOs
• SEQUEL Engineered Polyolefins
– 1400: thin wall
– 1500: mar resistant
– 1600: thermoplastic rubber
replacement
– 1700: low CLTE
Solvay Engineered Polymers
SEP Product Experience
• 1992 “Thin Wall” (3.0 mm)
• DEXFLEX 162:– Mazda 626– Mazda MX6– Ford Probe– GM U-Van– VW Beetle
• 1997 “Thin Wall” (2.5-2.8 mm)
• SEQUEL 1440/1402:– Mazda 626– Mercury Cougar– Ford Mountaineer Front Bumper– Chrysler LH Bumpers– Chrysler NS Bumpers– Chrysler WJ Bumpers (MIC
Metallic)– 22 more tools at Ford being
commercialized– 18 More tools at Chrysler being
commercialized
Solvay Engineered Polymers
SEP New Material Initiatives
• Thin wall parts:
– New advances in thin wall bumpers by extending SEQUEL® 1440 technologies to achieve 2.0-2.2 mm thick parts
• Body Panels:
– Continuing developments in polyolefin body panels through SEQUEL® 1726 and 1733 technologies
• Conductive Substrates:
– Exclusive manufacturing rights to conductive polyolefin materials. Current technology available in wide range of polyolefin materials.
• Olefinic Paint Systems
• Engineering resin conversion:
– Continuing development and implementation activities converting from engineering resins (PC, PC/ABS, PC/PBT, RIM, etc.) to Engineered Polyolefins
• Mold-In-Color Metallic
• Mar Resistance
• Paint Durability
• TPV Materials
Solvay Engineered Polymers
Development Capabilities
4000 Ton Battenfeld440 Ton Battenfeld
Pilot Paint Line
Introduced First Ford Fascia100% Sourced Ford Fascia
First Thin Wall Fascia withGas Assist
Master Source for all Color ApprovalsIntroduced First Post Industrial Recycle
Introducing exclusive Conductive material
Joint development with coinjection technology
Joint development with in-mold filmIntroducing high flow/high flex
technology
ResinDevelopment
StrategicJDA Activity
Solvay- PP- PE- Catalyst
PP Supply BaseAdditives Elastomers Paint Suppliers
CoreCompounding
Technology
Grand Prairie, TX Mansfield, TX
ApplicationDevelopment
BaseTechnology
AdvancedTechnology
Auburn Hills, MichiganFacility
Joint Development with Olefinic Paint System
Solvay Engineered Polymers
Automotive Applications
Development Center
• Advanced process technology
• Complete CAE capabilities
• 4000-ton and 450-ton presses
• OEM-certified prototype paint line
• Environmental chamber
• Application testing• Up to 18 months, historically to complete cycle
• 1 month at AADC
Complete application development via:
Paint Mold
Test CAE