The original power in motion.

www.dayco.com

®

HT. For new generation diesel engines.The Queen of Belts.

High Tenacitythe top-of-the-range white belt from Dayco production.

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1SEPTEMBER 2010

Editorial

This is communication!The Power in communication.

David MartínezGeneral ManagerAftermarket Division Dayco Europe S.r.l.

ur company has been inoperation for over a century.A long history in which wehave shown an extraordinary

capacity to maintain our objectives anddevelop business whilst respecting theinterests of all our partners. Our quality,innovation and professionalism, togetherwith the ability to adapt to the varioushistorical challenges, have ensuredconsistent success over the decades.However, experience has shown me thatthe true, added value which has placedthis company apart, has been its emphasison the concept of partnership. Through thecreation of good relations with both ourpersonnel and customers, we have beenable to form a strong “family unit” whichhas proved capable of confronting thechanges and overcoming the manydifficulties along the way. Today we canaffirm with humility but also awareness ofour strength, that we are once again readyand able to meet the future withconfidence. In fact, at this time of globaleconomic crisis, Dayco is re-launchingitself through an ambitious internationaldevelopment plan.

A challenging project in a difficult period,but we are convinced that Dayco has thequalifications to succeed. One of the most important instruments inour strategy is the strengthening ofcommunication both externally and withinthe company because we believe that animportant issue of today’s society is oftenthe absence of dialogue or simply poorcommunication. From this viewpoint, weare continuing to make significantinvestments in this sector and now withthis magazine we would like to provide afurther channel to communicate directlywith our friends and associates within thedistribution and repair sectors. This is animportant responsibility which we arepleased and confident to undertake.In the coming months we will instigateadditional updates, reorganization anddevelopment of our other communicationnetworks. A further vote of confidence inthe “health” of this company but above alla challenge to the market and especiallyto new and emerging markets where ourquality and professionalism can expand.This magazine, therefore, is not just aquestion of improving our image or

“making a good impression” on ourcustomers but it is a new and essential partof our development on the internationalstage. These pages represent for us asharing of our ideas, plans and targets forthe future and the renewal of a valuablerelationship which we hope to build upon,above all, with your participation. On behalf of the whole Dayco partnership,thank you and enjoy the magazine!

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4 6

13

A “conquest” for increasedquality

12

Belt in oil

Strategy as a mission: offering the best

The “Belt in oil” concept, designed anddeveloped by Dayco for original equipment,in co-design with the Ford engineeringdepartment, is an oil bath belt.

14 Prince

Produced in the Ivrea plant, “Prince” isa single-arm tensioner developed byDayco for the new motorisation PRINCEBMW-PSA

26 To be downloadedfrom the virtualgarage

Index

Increasingly wide range,increasingly clear instructionsand new informative tools

16Dayco plants: a combination of technology, innovation and organisation

®

New BER regulation:giving a hand toindependent repair shops

3SEPTEMBER 2010

D A Y C O M A G A Z I N E

World

September2010

Editorial

Marketing

Communication and Promotion

Product

Zoom

Research & Development

Garage

HT Kit transmission outlines

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4

6

12

18

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18 A new base inGermany

19 Long Life +1

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20Working with a fixed objective,focusing on perfection

Tailor-made courses: goodbye monkeyspanner, welcome to the “hi-tech” mechanic

24

eing the largest of theflexible transmission sectorhas never been Dayco’s finalgoal, but to be the best with

a driving force to achieve an increasingpresence and incisiveness on themarketplace is our target. The marketingstrategies have shown that the road tosuccess is to do more than just supplyingspare parts.“Our objectives - Bruno Vallillo, EuropeMarketing Director explains – havealways been to supply the productunderstood as a system. The latesttechnological evolution in the automotivesector proved us right”. Complex cars,high performance engines, reducedemissions and consumption as well asincreased reliability. For Dayco, supplying the maximumquality level both in terms ofproduct and in

terms of system, isstill not enough for us to feel thatthe company’s duties andmission have beenachieved. A furtherdecisive stepforward is

to supply all the information required toguarantee that the product is installedand maintained correctly.“Car repair shops - Vallillo continues –had to adapt, with new tools, withimprovements of their skills, andconsequently we have worked andprepared ourselves to anticipate themarket requirements”.

THE OBJECTIVE: NEVER BEING SATISFIED

Our achievements until now, through thespecial care, first of the product then ofthe system and the information, provethat Dayco is going in the right direction.What new objective could it have today?Definitely increasing information,

definitely extending the catalogue tocover ranges of less popular

vehicles and optimising thelogistic service through our

distribution network. “Thisyear, we have made

c o n s i d e r a b l einvestments – Vallillocomments – about amonth and a half agowe inaugurated our

new logistic base inGermany, but this is only

a first step. The objectiveis to take our product as

close to the market as possible,to be reactive, to allow our

distribution network to have what it

needs as quickly as possible, becausewe know that the mechanic needs thespare parts and we must supply them inthe most rapid and efficient manner.”

AN OBSESSION: INFORMATION

Dayco has invested and will keep oninvesting a lot in order provide the carrepair shops and the whole distributionnetwork with a high-leveltraining/information system based onspecialised courses, technicalinformation, leaflets, and focusing on theweb, through the creation of a dedicatedarea on the site www.dayco.com,designed for mechanics, with anevocative name: “Virtual Garage”. Anarea where the Group can communicatemore efficiently to the end-user, themechanic, who needs to receiveinformation punctually and quickly.“If a repair shop is independent - Vallillostresses - very often it does not havecomplete information as the informationis frequently transmitted throughauthorised assistance networks. Wemust not forget, however, thatindependent repair shops are the largestpart of the car repair sector”.Professionals who are often ignored bythe major suppliers and who must findby themselves documentation onproducts and techniques that changefrom one week to the next are a virginmarket to be conquered. Something to

Marketing

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Strategy as a mission: offering the best

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sink its teeth into for Dayco. “We mustnot forget – the Europe MarketingManager continues – that in theemerging markets, the technologicallevel has increased much more rapidlythan the past evolution of the ripemarket”.

SYSTEM SUPPLIER VS SINGLE PARTS

Dayco’s offering is very well-organised.It consists of two main areas: the systemsupplier concept on the one hand andthe single parts on the other. Thepurpose is to reach any market with thepossibility for the partners to choosewhat is needed for each single repair. A decisive choice since, even if thesuggestion is to choose the system withthe aim of optimising work in themedium term, the habit remains topurchase the single part. And Daycooffers this possibility.“We offer the best range – Vallillostresses - we actually cover more than95 percent of the European vehiclesegment. We offer all kinds of purchaseoptions: from single products to ‘turn

key’ kits. Our catalogue proposes over450 references for the kits alone. Weoffer the best levels in terms of productrange. We also offer the bestinformation, because we have investeda lot to provide the car repair shops andthe distribution network with a set oftechnical information that allow them tocarry out their work properly andquickly”.In the analysis of the choices made bythe customer, the increase of the kitsales is considerable in comparison withthe increase of the single piece sales.This further confirms that the systemsupplier logic is a winning logic.

LIGHT INDUSTRIAL VEHICLES, THE NEW FRONTIER

The range of Dayco products can bedivided into three groups. First the “Car”sector including light vehicles. Secondthe “Heavy Duty” sector includingindustrial vehicles and buses. Third thecycles sector which also includes, sincelast year, micro cars. These threefundamental groups, although they arevery different in size, are managed with

the same care and the sametechnological level.Dayco has dedicated a significantdevelopment effort to the industrialvehicle sector, a market that is verydifferent from the car sector, an irregularmarket as it consists of special vehicles.Dayco is a leading supplier for industrialvehicles, the first in Europe, and amongthe first three in the world for theproduction of rigid components forindustrial vehicles in the OEM sector.“Two years ago – Vallillo concludes –we started a total revision of ourcatalogue, with the purpose ofcompleting our range. This was not aneasy task considering the specificity ofthe objective, but we achieved itsuccessfully and we presented our newHD catalogue at the Automechanika Fairof Frankfurt. We are also working on theso-called light industrial vehicle, anothervery interesting sector”.

5SEPTEMBER 2010

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Communication and Promotion

A “conquest” for increased quality

ffectively Communicating toreach the head and theheart of the very wide“world” that revolves around

Dayco. From the customers, in all theirexpressions and organisations, to themany partners who, in their own way,meet and come into daily contact withthe multinational company. BehindDayco’s success lies effectiveCommunication and Promotion abreastof the situation, a sector which, like theothers, is in constant evolution. From2006 until today, the CommunicationPlanet has achieved the – oftenambitious - objectives that were set. In2006, at the Automechanika Fair ofFrankfurt, the new strategic line waspresented, with the purpose ofpresenting Dayco everywhere, alwayswith the same image. A “conquest” thatis at the basis of carefully studiedpositioning and branding strategies withvery clear medium and long termmarketing objectives. But Dayco did notstop here: still in Frankfurt, still at theAutomechanika, undoubtedly the most

important fair of the sector, this yearDayco presents its new style: a real“lifting”.Its objective? Reaching more directly andmore quickly the spare part dealers andmechanics or, as Franca Pierobon,Communication Manager, refers tothem, the repair professionals,considered as the new frontier, the newtarget, the market base that is the mostdifficult to reach. Using all the availablemeans: traditional and innovative,efficiently combined.“In 2006, in Frankfurt we presented thecoordinated communication concept –Franca Pierobon explains – whichsubverted the localised communicationconcept, focusing on a symbol thatexpresses energy, movement,dynamism, strength and resistance (thekey institutional and product concepts ofDayco’s world, editor’s note): The DaycoTrail with the slogan “The Original Powerin motion”. A symbol which, throughchromatic differentiation, identifiesimmediately not only thecommunication, institutional and

product lines, but also the productionlines: blue for institutionalcommunication and for Top products;orange for the HD-Heavy Duty line; goldfor the scooter and micro cars. In thesefour years, the Trail has consolidated itsimpact and is recognised by all thetargets that expressed theirappreciation. Therefore, it has becomea continuity element in the definition ofthe new communication format.” The ‘lifting’ defines a more direct type ofcommunication that uses the emotionaland absorbing characteristics ofevocative images, selecting subjectsthat the targets, including the ‘repair’professionals’ can immediately identifythemselves with. “In the past, our communication targetwas mainly the distributor, who can beof first or second class level, accordingto the market. Today, obviously, –Pierobon explains – as we move to thebase of the distribution chain, we haveto be more insightful, more devoted andcommunicate more directly”. In short, afundamental change.

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Communication and Promotion

THE CHALLENGE IN ITALY AND IN EUROPE

Once again, the challenge is ambitious:reaching with an efficient message thenew frontier of spare part dealers andmechanics, who in Italy alone, numberabout 34,000. If we project this figure tothe whole European scale, we canrealize the size of the market segment tobe reached. The CommunicationManager however, is not worried andexplains that “in spite of the longdistribution channels that characterisessome markets of the Automotive sector,Dayco is certain to be able tocommunicate with all the players in therepair sector, creating a kind ofsymbiosis, of valuable exchange oftechnical and market information. Weare obviously aware of the scale of thepotential, but we have years of

experience and market study”. Thedialogue strategy applied to the repairprofessionals was strongly considered,both because the company is aware ofthe ethic value of the relationshipbetween itself, the distributors and therepair sector, and because it is Dayco’shabit – and for this reason itsseriousness is appreciated – tothoroughly investigate the requirementsof its direct and indirect customers. “We have never considered themechanic – Pierobon points out – asthe minor link of the chain. On thecontrary, we are aware that he is the onewho can determine the fate of a productas he is the one who actually gives life tothe product by installing it on the vehiclesof his customers, who trust him. And we have the obligation to supply himwith products of the best quality, but alsoall with the information to install it

properly, because we do not want tojeopardise the high level of trust betweenthe mechanic and the driver.”This particular care for the repairprofessionals is fully expressed in theimplementation of a special areadedicated to them within the sitewww.dayco.com: the Virtual Garage. It takes just a few minutes to register andaccess a world in technical and detailedinformation. The activity presented forthe first time in Italy in 2009 at theAutopromotek of Bologna, is incontinuous implementation, and is nowavailable online for all the markets of themultinational company.

Torino

FORTHCOMINGNOVELTIES

Promotion and merchandising areanother two components of thecommunication mix implemented byDayco. Franca Pierobon does notdisclose the strategies butguarantees that from September,there will be many novelties and newgifts. There is a feeling of a prizecontest in the air. Keep checking theGarage area!”.

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roducts and informationcatalogues designed byDayco for its customersfollow parallel developments.

Ongoing evolution and new entries in theproduct range are followed by theimmediate updating of the catalogues,which are increasingly clear andaccessible. Dayco’s customer service isstrategic and punctual. For professionalrepair shops, the catalogue is not just aselling tool but also a valuable workingtool. The product-catalogue associationshows the extent of the company’sconsistent search for new componentsand improvement of the existingproducts, to cover significant parts of themarket. “Just to give an example, – theproduct managers CorradoBisegna and Gianluca Fantozzipoint out - our Autocatalogue can cover over95% of the Europeancirculating vehicle fleet.”This is an excellent resultconsidering that theremaining part consists ofold vehicles or brands that arespecialised in ‘high-spender’ targets. Togive further data, over the last year, thereferences in the three lines of productshave increased significantly: for the carsector, they increased from 2,514 in2009 to 3,565 in 2010. “Everyinformation –Bisegna and Fantozziexplain – is easily traceable in thecatalogue, which is available both on lineand on paper. Obviously, the web allowsimmediate updates, therefore we

suggest to visit the site and register to beinformed in real time.”The online catalogue also provides,through connected links, technical datathat allow the repair professionals to carryout their job in a correct, straightforwardand accurate manner. The mechanicswill find everything they need; fromimages to codes related to the varioustypes of cars, from the transmissionschematics & diagrams to replacementtechnical data.

THREE LINESAND THE KITS

Three lines of products are available:Auto, Truck (HD) and Cycle / Micro cars.This choice allows to provide thecustomer with a very wide service,covering practically the whole vehiclerange: from machines to buses andlorries. “We have introduced loose timingtensioners to provide an efficient solutionto any type of request, even though our

philosophy is to spread the ‘kit culture’ asmuch as possible, because we areconvinced that it is indispensible”Bisegna and Fantozzi explain. Thepurpose of the kit is to provide a completesolution that allows Dayco to have all thecomponents in a single box. Dayco’sefforts are constantly driven in thisdirection. “Everything must be there –the two managers of the productdepartment add - including screws andbolts, to give a better service. All the partsare purchased at the same time, whichis an advantage for the customer. And ofcourse, importantly, they are covered bythe comprehensive Dayco warranty.”

NOVELTIES

The new HDcatalogue offers anew line of

products, i.e. waterpumps. Dayco does not

produce them directly, butworks in close cooperation

with major producers whoguarantee the same Dayco quality, anessential requirement to enter intopartnership. A line of spare parts foragricultural machinery is also beingimplemented. The issue of the catalogueis planned for spring 2011. At the sameperiod, - or even earlier – an update ofthe Automobile catalogue will also bereprinted.

Product

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Increasingly wide range,increasingly clear instructionsand new informative tools

13SEPTEMBER 2010

Product

Belt in oil

he “Belt in oil” concept,designed and developed byDayco for originalequipment, in co-design

with the Ford engineering department, isan oil bath belt. Produced in the Chieti plantand assembled as part of a kit in Ivrea, theBelt in Oil is an efficient alternative to thetraditional chain control. The purpose ofthe Belt in Oil kit is to supersede the gearand chain system with a pulley and timingbelt system to provide functional benefits,reduced costs, whilst maintaining theperformance level unchanged. Thesolution offers various advantages amongwhich reduced friction between thecomponents and lower transmission

weights. The new system consists of thebelt, two pulleys, a hydraulic tensioner thatacts upon the upper arm of a slide whichin turn tensions and guides the belt, and asecond nylon slide, in the lower part, thatguides and supports the belt. The shapeof the slide has been designed to preventand reduce vibrations of the free section ofthe belt, allow its correct tensioning,optimise the meshing with the pulley,reduce friction and dissipate the generatedheat.The “Belt in oil”; which received importantawards (Ford European TechnicalAchievement 2008 and Galerìa deInnovaciònes 2009 Motortec – Madrid) isthe result of the ongoing technological

evolution and search for maximum quality,which have always characterised Daycoproducts and will keep on characterisingtheir future developments. This highlyinnovative product is in continuousdevelopment thanks to Dayco’s research.The R&D department is carrying out in-depth technical analyses, not only on newmaterials but also on the evolution of newoils, in close liaison with the majorcompanies in the industry. Their objectiveis to further investigate the possible effectson materials and allow futureimprovements of the productperformance.

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Prince

roduced in the Ivrea plant,“Prince” is a single-armtensioner developed byDayco for the new

motorisation PRINCE BMW-PSAIts constructive characteristic, patentedby Dayco, is the use of a special torsionbar as an elastic element, instead of thetraditional spiral spring. In particular, a“motorised friction wheel” is assembledin the PRINCE BMW-PSA engine, and

the pulley radial movementis operated by an electric

motor with

related reduction gear. The componentsare mainly assembled by hand due to thecomplexity and miniaturisation of theitems. A multi-function automaticcontrol station is provided and, like for allother Dayco products, endurance testsare carried out to simulate real-lifeoperating conditions.The result is remarkable: the water

pump pulley isconnected and

disconnectedby means of ane l e c t r i c a l l y

operated rollerthat receives the

movement from the

driving shaft, causing aquick increase of theengine operatingtemperature whilstreducing emissionsand consumption,since there is no drivewhen the water pumpis not needed.

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Product

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Product

Dayco plants: a combination of technology, innovation and organisation

irst-class production andquality assurance areamong the characteristicsof Dayco’s production sites

worldwide, in particular the Italian plantsin Ivrea and Chieti. These plants arerenowned for their technology,innovation and organisation and are incontinuous evolution, looking forappropriate and immediate answers tothe ongoing changes of the domesticand international markets.In both plants, the various productionlines reflect the high technological level,the use of the latest technologies and thesignificant commitment that lies behindtheir design and construction. Thecontrol stations and the checking ofmany constructive and functionalparameters, confirm how important thecorrect operation of the products can bein an endothermic engine, dispellingonce and for all the wrong impressionthat we are dealing with components oflower technological level. The productionand assembly operations are carried outon manufacturing cells that areconnected to an internal datatransmission network which allows theconstant monitoring of productivity andquality parameters.And there is more. The Italian productionsites make use of innovative machineryand rely on fully equipped laboratorieswhere in-depth analyses and tests arecarried out to guarantee the propertiesof the materials, identifying the causesof defects and failures and providingtechnical support to the market.Specifically designed test benches allow

to run a great variety of tests, recreatingthe most severe operating conditions

and determining the limits of the Daycoproduct in compliance with unifiedstandards and bespoke procedures, i.e.static, dynamic, impact and fatiguetests, with simple and complex stresses.

Ivrea Plant

The production site of Ivrea is based inthe industrial area in San Bernardo,where a historical Olivetti plant was built.Operating since 2000, it covers asurface area of 43,000 sqm, of which24,000 are covered; it currently employsover 600 persons.The production of the Ivrea plant isfocused on the engine rigid components,i.e.: dampers (pulleys) and tensioners forboth motorcars and industrial vehicles.The pride of the Piedmont productionsite is the single-arm tensioner for thenew PRINCE BMW-PSA motorisation. Itsexclusive design, patented by Dayco,uses a special torsion bar as elastic

element, instead of the traditional spiralspring.

Chieti Plant

The other important Dayco productionsite is based in Chieti. The plant, locatedin the industrial area of the Abbruzzotown, occupies a factory which used tobelong to Pirelli. It became operational in1993 and produces the engine flexiblecomponents, i.e. the belts. The Chietiplant is very impressive and covers atotal surface area of 79,115 sqm ofwhich 22,391 are covered. It currentlyemploys 400 persons.One of the leading products of the Chietiproduction site is certainly the “Belt inOil”. A special, resistant oil bath belt.Designed and developed by Dayco fororiginal equipment, in co-design withFord engineering department, the “Beltin oil” is an efficient alternative to thetraditional chain control.

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Zoom

A new base in Germanyhe cradle of the automotiveindustry could not but havea Dayco-brand centre ofexcellence. The dynamicGerman market is for Dayco

a privileged showcase and, to enable it tomanage its relationship with attentive anddemanding customers in an efficient,prompt and innovative manner, Dayco haslaunched a new logistic platform coveringan overall surface area of 1,550 sqm.This investment allows to program amulti-level propulsive strategy, based oncapillary distribution, a detailedorganisation, efficient logistics, clearcommunication and, obviously, qualityproducts.The new centre offers all the potential toguarantee improved service at alldistribution levels: through this centre,Dayco can provide increased punctualityto execute the orders, as well as improvedefficiency and a more satisfactorydistribution network.By way of example, with the complex or-ganisational structure working on the newplant, Dayco can reach minor customersdirectly. Even twice or three times a week.From this significant launching pad,

Dayco’s overall growth strategy will reachall the distribution levels of the Germanmarket.“The relations with the most faithfulcustomers will be consolidated –MilkoWolf, Regional Sales Manager of DaycoGermany explains with satisfaction – and,in parallel to this, direct dialogue with thespare parts dealers and the mechanicswill be implemented ”.

IDENTITY CARD OF THE NEW BASE

The special characteristics of the newDayco warehouse, operational sinceAugust, are the wide choice of productsand the favourable logistic location.The new distribution unit is based in SouthOvest Germany and can benefit from theresults of the cooperation between Daycoand a local strategic partner. The base hasbeen implemented with the clear purposeof fulfilling quickly and punctually thecustomers‘ requirements.

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19SEPTEMBER 2010

Long Life+1 is a significant addition tothe Garage area and the starting point ofa highly “advanced” onlinecommunication dedicated to the end-users, in particular the repairprofessionals, i.e. the mechanics. LongLife+1 is a one-year warranty extensionfrom the current two years to three

years. This commercial warranty isrelated to the assembly of Daycoproducts, exclusively reserved for carrepair shops. The warranty extensionwill only apply to kits containing the HTbelt, in particular timing kits, includingthose containing the water pump.Through simple steps (registration,

entry of serial number and vehicle data,acceptance and confirmation) themechanics will be able to print thewarranty certificate and make use of theextension. The serial number – a codeincluded on the product label – isessential and represents, together withthe registration to the site, the starting

point to obtain the certificate. Long Life + 1 will soon be promotedthrough an information campaign anddirect promotional activities, initially onthe Italian market, before spreading toall markets.

Zoom

New BER regulation:giving a hand to independent repair shops

valuable support designed toguarantee the interests ofEuropean drivers, making thecar maintenance market

more competitive, more reliable and lesssubject to the uncontrolled increase of theoperational prices. These are the guidelines at the basis of thenew “Block Exemption Regulation” (B.E.R.),which became effective on June 1st, 2010and will be valid until May 2023.

WELCOME TO “EQUIVALENT QUALITY”SPARE PARTS

One of the principles of this new regulationis the approval given by the EuropeanCommission to the use of spare partsoffering a quality equivalent to the original,including from the approved car repairshops. An important principle already setout in the previous edition of the B.E.R. wasalso confirmed, i.e. the use of equivalentparts by independent repair shops does notcompromise the vehicle warranty providedby the car manufacturer.

PROTECTION OF FREECOMPETITION

“In the new version of the regulation, theCommission has made an exceptionaleffort to guarantee equity and freecompetition” – Riccardo Bosco, salescoordinator, explains.In particular, the new B.E.R. regulationdefines three strong points. First, the authorised channel will be ableto supply original components toindependent repair shops, increasingtheir operating capacity.Second, the component producers willbe able to supply spare parts toauthorised repair professionals andindependent repair shops, widening therange of options available to drivers whorequire an operation on their vehicle.Third, the component producers willhave the right to apply their own brandon the car manufacturer’s OEMproducts or spare parts.“A further decision benefiting andprotecting independent repair shops–Riccardo Bosco continues- was thestrengthening of the principles providing

for the obligation to make available andeasily accessible to independentworkshops the technical information forrepairs and maintenance, and access todiagnostic tools”.

A CONCRETE EXAMPLE: THE CHOICE OF IVECO.

What Iveco published on its web site issignificant. The Fiat Group company hasdecided that access to corporate know-how will be shared between repairshops, distributors and auto clubs whichwill benefit from the assistance networkwhereas companies, operators andproducers who will have to contact theCustomer Service of the Turin company. With reference to the transfer oftechnical know-how – this can be readon the Web site – the (EC) Regulationno. 1400/2002 sets out that all the so-called Independent Operators offeringrepair and maintenance services shouldbe able to have access to the sametechnical information, diagnosticequipment and tools, made available bythe manufacturers to their service

network. Access to this informationshould be guaranteed with prices andtimes that are not discriminating ascompared to the authorised network.Furthermore, prices should beproportional to the amount of requestedinformation.

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INDEPENDENTOPERATORS

According to Article 4, paragraph 2,independent operators include:- independent repair shops- independent distributors of spare

parts- automobile clubs- companies publishing technical

information- operators offering training services to

repairmen- producers of repair equipment and

material

Long Life +1

R&D - Research & Development

esearch is paramount. This iswhat Dayco Group’sinnovation is based upon. It isthen improved in each

subsequent stage with methods that areclose to perfection. In substance, Dayco’sResearch & Development highlights andcharacterises every activity of the Group.Their mission is centred on a simple yetwinning motto: innovating to confirmworldwide leadership. It is not a coincidenceif Dayco invests massively in R&D: a greatnumber of professionals operate within theinternal structure, searching for newopportunities. And the results are tangible:

from the successful Belt in Oil and torsionarm for the Prince engine to the HT beltusing the teflon technology. The R&Ddepartment is involved in every aspect of theprocess.Going into detail, the R&D Department is incharge of the development of all materialsand products, both in terms of flexiblecomponents and rigid components. Based on the customers’ requirements,new, high performance material can bedeveloped to fulfil more accurately therequests of an increasingly selective andunpredictable market. And also: Dayco’sresearch is capable of experimenting and

producing innovative production solutions.More efficient and more reliable, a perfectcombination to reach the standardsrequested by the customers. The achievement of increasingly ambitiousobjectives is met through extensive teamthat work ready to transform an innovativetechnical idea into mass production for theautomotive sector. This is possible thanks to the most valuableresource of a company: its co-workers.Dayco has understood this concept andinvests every year in training courses andrefresher courses.

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Working with a fixed objective,focusin g on perfection

21SEPTEMBER 2010

ATTENTION TO DETAILS

Upstream the Dayco product, theprocedures “suggested” by the researchand development sector are applied to thewhole process: from the materials to themanufacturing techniques, through theproduction of rigid and flexible components. The search for better solutions never stops– both for flexible and rigid components.“We can develop new materials - CarloBaldovino of the Research departmentexplains – starting from new polymers andchemicals, in cooperation with leadingsuppliers such as Zeon and Bayer,companies with which we share commondevelopment projects”. Dayco R&D runs numerous trials and tests,including dynamic life tests and chemicaltests. On completion of the tests, samplesare produced and tested in extremeconditions: cold, heat, humidity, oil, fuel, etc.Control is carried out on two distinct stages.First on the test bench: an electric engine

capable of reproducing the layout of a realengine is monitored constantly by thecomputer which analyses each data to allowthe researchers to interpret them. Thesecond stage – the final one – is carried outdirectly on the reference engines. “We followthe development of all materials andproducts – Baldovino continues. Based onthe requirements of the customers and themarket, we can develop innovative, moreefficient materials that better fulfil theapplication requirements”.

CONTINUOUS EVOLUTION, A CONCEPTBETWEEN CUSTOMER AND SUPPLIER

Every year, the Research sector issuesvaried proposals of innovative products, atthe request of and in strict cooperation withthe major car manufacturers. “We haveloads of new projects – Baldovino explains– because every engine has alwaysinnovative components” It is a process in

continuous evolution and, for this reason,cooperating with both the raw materialsupplier and the customer is vital, as it allowsus to obtain information on a new material,sometimes developed in a totally differentsector, which proves to be functional to theproject and is used to improve the product,thanks to the intuition of Dayco’sresearchers. This too is part of the know-how.

FROM RESEARCH TO THE PRODUCT.A CONCRETE EXAMPLE: THE CREATION OF A BELT

An example is more useful than a thousandwords. The belt production procedure is agood example to understand howmeticulous Dayco Research is. The firststage in the belt production is the choice ofthe raw material. This is the task of theResearch & Development departmentwhich, based of the engine functional cha-racteristics, must choose a materialcomposition that will allow to fulfil therequirements in terms of performance,mileage and life time of the finished product.The belt prototyping and tests on the finishedproducts are possible only after completionof thorough tests on the material. This stage,usually carried out in cooperation with the

car manufacturer, includes various stepsand various test conditions: some aresimulated in-house, other are performed“on the road”. After the prototype is finalised, the belt canbe industrialised and subsequentlyproduced.Industrialising a product is an extremelydelicate process in which the R&Dtechnicians play a critical role. It is actuallytheir job to evaluate and adapt the designingrequirements to the industrial requirementsto provide the customer with the exact cha-racteristics and their constant quality level.This stage also relies on the efficient teamwork between the technicians from theproduction, research and quality controldepartments. The customer must not faceany problem. This is the common spirit thatkeeps a group of people united in their dailyactivities. Once the results are achieved, theproduction can start. It is constantlymonitored to guarantee a constant qualitylevel, including on mass production items.

R&D - Research & Development

Garage

2 4 POWER WORLD

n the modern automotive market, thetraditional image of the mechanic hasgreatly evolved through technical andcultural preparation. In today’s

workshops, the mechanic must haveknowledge in a lot of different fields:mechanics, of course, but also computerscience and electronics. The mechanic isessentially a true professional and, beingthe last link of the chain, he is the oneresponsible for the success of a givenproduct. This is one of the reasons, butnot the only one, why Dayco takes greatcare & values its mechanics. So much sothat it has created a group of technicianswho travel all over Europe, assisting themechanics through technical courses andhotline services. The periodic reportsdrafted by the technicians allow theMarketing Department to designincreasingly efficient product andcommunication strategies, speciallysuited to the customer.“Based on our experience – PinoMacchia, Junior PM & TechnicalCoordinator explains – we try, during thecourse, to anticipate the questions,explaining the possible failures of theengine, highlighting the new products,disassembling the components and

comparing them with the competitors’.We show the results of the lab tests andwe explain to the mechanics why we usedetermined materials rather than othersand how they can identify immediately aDayco piece from a non-Dayco piece”.Significant contribution is given by thelocal distributor and the spare partsdealers who, in cooperation with Dayco,define the date and location of the course.The invitation to attend the course iscurrently extended to the mechanicsthrough the customers. The number ofparticipants ranges from 20 to 30, and thecourse covers the most varied subjects.The course starts with an overview of theDayco Group: its history, evolution,mission, major customers, presence atworldwide level. The various plants areillustrated, in particular the productionplants. Then the course focuses onresearch and development, a sectorDayco is very committed to. Every year,the Group invests in research to generateand find new materials guaranteeingimprove performance. The next stagedetails the range of Dayco products: rigidcomponents, tensioners, dampers,mechanical belts. “We also explain –Macchia goes on - how the products are

manufactured, for example how the Beltin Oil is produced. Then we makeperformance comparisons, using videosthat show in detail the operation and thelong process required to produce the itemthat they (the mechanics) use, forexample bending tests, endurance tests,wear and fatigue tests, etc.”Mechanics attending the Dayco courseare also involved in a diagnostic partwhich examines in detail the mainproblems resulting from an incorrectinstallation of the spare parts, supportedby technical data sheets and videos shotwith special cameras, that show, forexample, what happens when the belt isnot installed correctly or how a belt toothjump can occur. These cameras areextremely sophisticated and can take15,000 photograms per minute whichallows to stop the image in any singlemoment.Videos demonstrate the damage to a beltthat is not installed correctly or thefunction of the Dayco products, such asthe damper.

Tailor-made courses: goodbye monkey spanner,welcome to the “hi-tech” mechanic

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5 simple steps for one more warranty year

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Get informed and download the certificate of warranty extension from our web-site:

Certificate of Warranty Extension warranted quality

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2 6 POWER WORLD

Garage

arious information toolsare available in the virtualGarage area of the Daycosite and can be

downloaded free of charge. The first isthe “Technical Information”. Created asa supporting tool for professional repairshops, they provide solutions to dealwith any kind of problem. They havenow become useful technical datasheets on assembly procedures,complete with all the necessaryinformation. “The transmission layoutsare attached to the document –Bisegna explains -. According to thevehicle being revised, the mechanic candownload the suitable layout.” Thisvaluable tool helps to reconstructquickly the layout in the workshop.

There is also the “Product Information”,published every time a new product islaunched. The sheet is sentautomatically to the customers who areregistered in Dayco’s mailing list,obtained from a database of the peopleregistered in the Garage area. Inaddition, the catalogue is updatedimmediately, in order to keep the end-user’s interest alive. The last generation of information is the“Service Information”, a sort oftechnical updating that further detailsthe product. “For example – Fantozziadds– if three seemingly identicaltensioners are available, we help themechanic clarify the situation,understand the differences and identifythe most suitable item. This is service

information, directly related to theproduct”.The product assistance activity does notstop here, Franca Pierobon,communication manager, explains: “Weare developing a series of informationtools that can reach directly the repairprofessionals through the VirtualGarage, but also through otherchannels, directly into their workshops”.The objective is to provide tools that areincreasingly efficient and direct.

To be downloaded from the virtual garage

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2 8 POWER WORLD

KTB459

159

KTB296

KTB342 KTB360

Update HT Kit transmission outlines

Croma

Astra

9.3

Astra

A2

Galaxy

Altea

Oktavia

Golf

A3

Leon

Oktavia

Golf

A3

Galaxy

Alhambra

Superb

Sharan

2 9SEPTEMBER 2010

KTB441 KTB373

KTB493 KTB532

Update HT Kit transmission outlines

Sandero

Note

Modus

A4

Toledo

Oktavia

Passat

A4

Passat

C3

Scudo

Fiesta

3

Mini

207

3 0 POWER WORLD

KTB460 KTB470

KTB283 KTB440

Dacia Focus

Clio

Transit XF

607

Update HT Kit transmission outlines

31SEPTEMBER 2010

KTB414 KTB267

KTB359 KTB294

Corsa Arosa

Felicia

Polo

Leon

Golf

Sharan

Update HT Kit transmission outlines

The new 2011 HD catalogue is ready

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