HARNESSING THE POWER OF INNOVATION FOR NEXT GENERATION LIGHTWEIGHTING TECHNOLOGIES Lyle Otremba Innovation and Advanced Product Strategy

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“Everything that can be

invented, has been invented.”

Charles H. Duell Commissioner, U.S. Office of Patents 1899

George Carlin

“Put two things together that have

never been put together before, and

some schmuck will buy it”

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Innovation Process Based on Customer Needs

•  Culture •  Process

•  Organization

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Project Evaluation Scorecard Helps Identify and Prioritize Projects

•  Ideas are scored to determine importance / viability

•  Above “60” achieves assignment…

•  GTC determines where

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Global i3 Portal Generates Projects

323 Total i3 Submissions

204 Selected Ideas

59 Global Innovation

Ideas

15 Active i3 Projects

9 High-Active i3 Projects

Innovation team focused here

7 Innovation Projects have come through the i³ process…

“Idea Inventory”

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• Creates need for quieter interiors • Will affect vehicle ownership

model and durability requirements

• Technology is ahead of policy

• Requires weight reduction • Adherence to green materials &

processes •  Introduces alternative powertrains • Public slow to adopt

• Produced in two or more regions • Common global architectures:

fewer platforms, more variants • Well positioned suppliers gain

market share • Regional suppliers left behind

Global Platforms Autonomous and

Connected Vehicles Emissions / Fuel

Economy Legislation Globally

Global Trends Three Key Drivers (“MEGATRENDS”) Will Impact the Industry for the Next Ten Years

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Automotive OEMs: Challenges Ahead…

2015 Target

2020 Target

Mass is the single, largest driver for emissions

Source: European Environment Agency Data 10-2014

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Engine Mount Lightweighting Solutions

Thermoplastic PA 50% Short or Long Fiber Solutions already in serial production

Thermoplastic Composite : DYNAFIB Results in Strongest Part Lightest Weight Option

Hybrid Metal/thermoplastic Limited weight saving

Thermoset Composite Long cycle time Difficult Rubber to Metal bonding Several projects on-going

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The Project: Thermoplastic Composites Reinforced with Continuous Fibers

Project : DYNAFIB Project Overview

“A strategic effort to develop a process enabled composite part design, targeting a 50% weight reduction versus metal based AVS solutions”

Reduce  Weight  and  Maintain  or  Gain  Strength  to  Parts  

DYNAFIB Performance

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Project : DYNAFIB Development Process

MAY 2014 JUNE 2016

Material Selection June 2013-2014

Process Parameter Definition June 2014 - Mar 2015

FEA Modeling Nov 2014 - Sept 2015

Process and Product Validation June 2015 - June 2016

STEP 1 STEP 2 STEP 3 STEP 4

G1 G3

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Reinforcement Manufacturing Thermoplastic Overmolding

Project : DYNAFIB Mass Production Process

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50% Weight Savings

Engine Mount Application Torque Rod Application

Project : DYNAFIB Applications

35% Weight Savings

Structural Part Application

40-50% weight savings

Significant Weight Reduction Now Possible in Key Structural Components

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Fortrex™ : Transforming the Future of Weatherseal Systems

BENEFITS §  30%+ Mass Reduction Versus Dense EPDM

§  10%+ Mass Reduction Versus Dense TPV

§  Superior Compression Set Characteristics

§  High Elasticity Performance

§  Non-Conductive, Non-Blooming, Non-Fogging

§  Exceptional Weathering Performance

§  Improved Scratch Performance

§  No VOC's (Volatile Organic Compound), No Nitrosamine

§  Broad Color Matching Capabilities

§  Improved NVH and acoustic Performance Over Time

TARGET APPLICATIONS §  Frame Under Glass- Glass Run

Systems

§  Channel Mounted- Glass Run Systems

§  Inner Waist Belt

§  Outer Waist Belt

§  Below Waist Extrusion

Fortrex™ is a next generation Lightweight elastomer that delivers superior sealing, weatherability, NVH, and gloss performance.

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Bringing New Ideas to Customers Creating New Products to Make Cooper Standard Stronger

ArmorHose™, ArmorHose™ II, and ArmorHose™ III Eliminates requirement for protective sleeves on hoses

Reduces weight and labor costs

Provides a recyclable and extended-life option

MagAlloy™ Coating Improves corrosion performance and product life utilizing proprietary technology

Exclusive to Ultra Nyclad and UltraPro Coat Products

Fortrex™ Sealing Revolutionizes sealing industry with new material science

Reduces weight, improves performance, and offers appearance options

Gen III Quick Connect Improves connections with sensor capability

Quick connector with integrated sensor for pressure and temperature measurement of fuel and vapor

Simplifies systems; reduces mass and complexity