The Value of Teamwork

1
The Value of Teamwork !

• There are no problems we cannot solve together,
  and very few that we can solve by ourselves.
• Lyndon Johnson
• We should not only use all the brains we have,
  but all that we can borrow.
• Woodrow Wilson
• People have been known to achieve more as a
  result of working with others than against them.
• Dr. Allan Fromme
• Great vision precedes great achievement.
• John C. Maxwell
• You can do what I cannot do. I can do what you
  cannot do. Together we can do great things.
• Mother Teresa

2
Southfield Engineering Team

• Edgar Espinoza Myung Shin Earnest Payne
• Stacey Bentley Fred Kelley Joe Kerul

3
Southfield Engineering Team
Art Siewert Mark Grandy and Mr. Bunny
4
Southfield Engineering Team
Mike Trafton Mark Hester
5
Engineering Development ProjectsPrestolite
Weight Loss Plan

• Skinny Copper

6

• Presto-Lite TM is a new wire product developed
  by Prestolite Wire
• Corporation that brings the advantage of
  lighter weight, increased
• flexibility and reduced dependence on price
  variations of copper.
• Combined with Prestolite Wires technology
  leading jacketing materials
• to provide new lighter weight wire,
  Presto-Lite TM is the ideal product for
• customers to improve the feature of
• end-products while reducing cost!!!

7

• Weight savings of Presto-Lite TM material vs.
  copper of equal gauge size is 63.
• Weight savings when using next bigger gauge size
  of Presto-Lite TM material vs.
• Copper can be as high as 45.

7
8
Marine Applications

• ABYC National Meeting in Annapolis, MD
• Electrical Project Technical Committee
• July 26 and 27, 2006
• Prestolite has been invited to attend the meeting
  as a technical expert to speak on our
  Presto-Lite wire products.
• Prestolite was asked to develop and present
  technical information for CCA electrical
  performance and wire size selection per the
  current ABYC format.
• BH Electronics will present applications were
  this technology can benefit the marine industry.
• The Commit Form is complete and delivered to
  the board.
• The Interpretation Form is complete and this
  item is on the conference agenda.
• The committee is expected to accept for immediate
  implementation to avoid waiting until a new
  publication of the entire specification.

9
ABYC Technical Meeting Presentation
10
Heavy Truck Applications

• Mack Truck
• Validation Testing
• Battery Cable Assemblies
• 2/0 gauge Prestoflex CCA
• Test plan review complete
• PWC ES-2287 created.
• Cable Testing
• Assembly Visual Review
• Terminal Pull-Off
• Voltage Drop Testing
• Current Cycling Testing
• Temperature Humidity Cycling
• Thermal Shock
• High Temperature Exposure
• Severe Vibration Testing

11
Sizing Cables Odyssey Benchmark Study
The BM/MD battery cable is made out of 3
different cables
To keep similar electrical characteristics, when
changing from Copper to Presto-Lite TM material,
a cable construction needs to be
modified. Option 1 Increase the wire size
12
Sizing Cables Odyssey Benchmark Study
BM/MD battery cable
Option 2 Change the insulation
13
Skinny Copper

• Two key areas of work
• Primary sizes (8ga to 22ga) Cable sizes (6ga to
  4/0) with focus on the top 20 copper volume items
• What is under scrutiny?
• Lay length increases
• Increase throughput
• Reduction in copper usage
• Specification Harmonization
• Reviewing product line requirements to minimize
  the amount of copper by reducing our tolerances
• Verifying that all specifications that product is
  manufactured to are in harmony (example if wire
  is made to SAE, Ford and Chrysler specifications
  but the three specs have different copper
  requirements, do we re-design copper that meets
  each of the three specs or continue with a
  communal engineered strand).
• Processing Capabilities
• Analysis of bare wire and extrusion processing
  steps to determine impact and capability. Can we
  tighten up the tolerances windows for the copper
  content? Can the equipment handle it? Do we
  need investment? Examples in tension controls
  (reduction of variation in extrusion pull down of
  copper), pay off equipment (draw down of copper
  when paying due to force), MW (consistent 8 wires
  vs. single end machine capability)

14
Skinny Copper Delphi Program