26
COMPANY & PLANT OVERVIEW 2014
COMPANY & PLANTOVERVIEW 2014
Company Profile General
Based on 2012 data
Cable, Highland Heights, KY
Net Sales(1)
Publicly Traded
Associates
Plants
$6.8 Billion
NYSE: BGC
14,000
57
Manufacturing in 26 Countries
Number 421 on the Fortune 500
(1) Reflects 2011 pro forma net sales including Alcan Cable North America , Procables and Prestolite Wire
2
General Cable’sLocations
North American
Lapointe, QC
La Malbaie, QCSt. Maurice, QC
St. Jerome, QC
MonManchester, NHtreal, QCWoodbridge, ON
Toronto, ON
Roseburg, OR(currently idle) Franklin, MA
Lincoln, RISouthfield, MIWillimantic, CTDes Plaines, IL
Marion, IN Williamsport, PAAltoona, PALebanon, IN
Indianapolis, IN Highland Heights, KY
Lawrenceburg, KYSedalia, MO
DuQuoin, ILNorth Hollywood, CA Chino, CA Jackson, TNParagould, AR
Malvern, ARAtlanta, GAMarshall, TXNogales, AZ
Nogales, Sonora, MX
Houston, TXEagle Pass, TXPiedras Negras, Coahuila, MX
Headquarters
Distribution
Manufacturing
Offices
Technology Centers
Doral, FLMonterrey, Nuevo Leon, MX
Mexico City, MX
Tetla, Tlaxcala, MXCuernavaca, Morelos, MX
3
The Global Wire & Cable Market
Report Revenue in Billions
Prysmian Group
$0 $3 $6 $9 $12Source: Integer Research, Based on 2011 reported revenues
*2011 General Cable Proforma results including Alcan Cable North America, Procables and Prestolite Wire acquisitions
With the Alcan Cable, Procables, and Prestolite Wire acquisitions in 2012, General Cable became the third largest wire & cable company in the world
4
Prysmian Grou
Nexans
General Cable
LS Cable
Southwire
Sumitomo Electric
Furukawa
Willimantic, CT Facility
Industrial & Specialty Cables
Manufacturing Excellence, Willimantic, CT
Facility Facts:
Plant built in 1942 for Pratt & Whitney
Purchased from BICC Cables in 1999
655,000 Square Feet of Manufacturing and Distribution Space
300 Associates - 230 Union
Union Seniority - 20 Years on Average
Salaried Seniority – 17 Years on Average
2012 Plan Cost of Production - $ 210M
Capital investment of $11M in 5 years
Product Quality &Assurance
Product Quality:
• Extensive In-house Testing Capabilities
Physical, Electrical, Environmental, Flame
Per UL, CSA, Mil Spec / NAVSEA, IEEE, ICEA
Certificates of Compliance, Certified Electrical Report and
Certified Test Report Capability•
Quality System:
•
•
•
•
ISO 9001:2008 Certified (UL/DQS registered)
USNRC 10 CFR 50 Appendix B (U.S. Nuclear Quality System)
ASME NQA-1:2008 (International Nuclear Quality System)
International Railway Industry Standard (IRIS) Certified (UL/DQS
registered)
NUPIC and NIAC Surveillance
MIL-STD-790 Product Assurance Certification
Type Approvals for Lloyd’s Register, DNV and ABS (Marine)
CSA Category Program for Testing (2nd party approval to ISO
17025)
UL Data Acceptance Program (2nd party approval to ISO 17025)
•
•
•
•
•
Transit Experience – Wire and Cable
GE Transportation Systems/Locomotives
WMATA 2K/3K & WMATA 6K-Alstom
PATCO, Montreal, MBTA, Amtrak NEC-Alstom
Denver, SCRRA, SEPTA, MBTA, State of Florida-Rotem
R179, CTA, NJT, Vancouver, KL, BLEP, Montreal-Bombardier
ViaRail Loco’s, GO Transit-Canadian Allied Diesel
Amtrak Locomotive-Siemens
NFTA-Ansaldo Breda/GMI
Amtrak Viewliner, Houston-CAF
METRA, VRE, SMART, Metrolinx-Nipponsharyo
8
Piedras Negras, Mexico
Harness & Assemblies, Transit
75,000 ft. manufacturing spaceFlexible cellular configuration designedfor quality focused single piece flow350 total associatesISO 9001:2000IPC A-620 certifiedIRIS certified
Only North American Wire HarnessManufacturer
9
Revenue Segmentation
Customer Base Focused on Industry LeadersGeneral Cable Harness market
Transit Medical Industrial Military Energy
10
Transit Experience – Wire Harnesses
• General Cable wire harness and assembly division in operation for over twenty years
• GCC Value Proposition
•
•
•
•
Low cost country position
Vertical integration with wire & cable
Purchasing power of $50M per year operation
Backing of a financially stable organization
• Certification to International Railway Industry Standard (IRIS)
•
•
Only Wire Harness operation in North America that is certified to IRIS
Wire Production facility also certified
• Customer and Project Experience ListBombardier:Vapor Rail:Alstom:Sepsa:Amtrak:CTA:TTC:
ECAM/NYCT, Toronto, BART, CTA, WVA, Montreal, JeddahR-160, PATH, SCRRA, CTA, Amsterdam, AmtrakR-160R62aAmFleet I & II in-house rebuild programsMotor Traction Lead Replacement ProgramLRV Streetcars
GE Transportation: Locomotive production
11
Product Types
Equipment Control Harnesses Harness Board OperationsFiber Optic Assemblies
Industrial Wire HarnessesConnectorized OEM Products
12
Product Overview
♦Our most competitive products are
medium to highly complex wire
harnesses and cable assemblies
♦Typical products include either
assemblies with high GCC cable
content or complex harnesses with
high labor content
♦Our typical customer has a high
number of SKUs with volumes
ranging from a few pieces per
year to several thousands
13
Tinned Copper20 AWG -1111kcmil
Features:
Proven history of performance for over 25 years
Irradiated Cross-Linked Insulation System; 20 AWG to 1111kcmil
Class I conductor stranding, Class K optional
Special 3KV constructions for Amtrak (HHP Locomotives)
Excellent Flame Retardance
Qualified to IEEE 1202, IEEE 383, VW-1, & NFPA 130 STD 2010
Outstanding Oil Resistance
Superior Mechanical Performance
Meets cold bend test at -55C
Meets cold shock test at -40C
Low Smoke, Low Toxicity
Qualified to ASTM E662, BSS 7239, & SMP 800-C
Single Wall Extrusion
Compliant to AAR S-501 / AAR RP-585 & ICEA S-95-658 Wiring and Cable Standards
600V 30 mils minimum wall thickness
2000V 45 mils minimum wall thickness
Polyrad® XT(XLPO)insulation
Tinned copper 22AWG – 10 AWGFeatures:
Irradiated Cross-Linked Insulation System; 22 AWG to 10 AWG
Class I conductor stranding
15 Mils Nominal Wall Thickness
Excellent Flame Retardance
Qualified to IEEE 1202, IEEE 383, VW-1, & NFPA 130 STD 2010
Outstanding Oil Resistance
Superior Mechanical Performance
Meets cold bend test at -55C
Low Smoke, Low Toxicity
Qualified to ASTM E662, BSS 7239, & SMP 800-C
Dual Wall Extrusion, XLPO/PVDF
XLPO
10 mils nom.
PVDF
5 mils nom.
Total wallthickness
15 mils nom.
Reduced diameter and lighter-weight transit wire: up to 33% smaller in diameter
and lighter in weight than conventional Polyrad® XT 600V
Multi-Conductor Cable Construction Options
Primary Wires: 600V (Polyrad® Ultra only) and 2000V constructions
Cable Core:
Non-Hygroscopic Flame-Retardant Fillers
Non-Hygroscopic Tape Binder
Shields:
Tinned Copper Braid, min. 85% coverage
Aluminum/Mylar Tape with Drain Wire
Unshielded
Nylon “Skip Wrap” Binder
Jacket Systems:
XLPO, Neoprene, or LSZH
Optional Armor (Polyrad® XT only)
Galvanized Interlocking Steel
Aluminum
Composite Cable Design Options
Features:
All the physical characteristics and properties of Polyrad
compliant formulation
Class I conductor stranding, Class K optional
Irradiated Cross-Linked Insulation System
Outstanding Electrical Performance
High Ampacity Ratings
Tinned Copper
XT and Polyrad Ultra in a RoHS
Polyrad® XT(XLPO)insulation
Excellent Flame Retardance: Qualified to IEEE 1202, IEEE 383, & VW-1
Outstanding Oil Resistance
Superior Mechanical Performance
Meets cold bend test at -55C
Meets cold shock test at -40C
Low Smoke, Low Toxicity
Qualified to ASTM E662, NFPA 130 STD 2010, BSS 7239, & SMP 800-C
Single Wall Extrusion (Dual wall for Ultra)
Compliant to AAR S-501 / AAR RP-585 & ICEA S-95-658 Wiring and Cable Standards
Like Polyrad® XT, also available in multi-conductor shielded and unshielded constructions
Restriction of Hazardous Substances (RoHS) Directive
RoHS specifies maximum levels for the following six forbidden materials:Lead (Pb): < 1000 ppm (0.1%)Mercury (Hg): < 100 ppm (0.01%)Cadmium (Cd): < 100 ppm (0.01%)Hexavalent Chromium: (Cr VI): < 1000 ppm (0.1%)Polybrominated Biphenyls (PBB): < 1000 ppm (0.1%)Polybrominated Diphenyl Ethers (PBDE): < 1000 ppm (0.1%)
•RoHS is often referred to as the lead-free directive, but it restricts the use ofthe six substances•Each country/organization has its own list of chemicals in addition to RoHSrestricted chemicals! For example, Bombardier lists antimony oxide as arestricted chemical
18
Tinned Copper20 AWG – 4/0(600V)
20 AWG –535kcmil(2000V)
Features:
Formal technical approval to the NYCT TX Specification
Irradiated Cross-Linked Insulation System; 20 AWG to 4/0 in 600V; 20awg to 535kcmil in 2000V
Outstanding Electrical Performance
High Ampacity Ratings
Excellent Flame Retardance
Qualified to IEEE 1202, IEEE 383, VW-1, & NFPA 130 STD 2010
Outstanding Oil Resistance
Superior Mechanical Performance
Meets cold bend test at -55C
Meets cold shock test at -40C
Low Smoke, Low Toxicity
Qualified to ASTM E662, BSS 7239, & SMP 800-C
Single Wall Extrusion
Compliant to AAR S-501 / AAR RP-585 & ICEA S-95-658 Wiring and Cable Standards
Also available in multi-conductor constructions
Polyrad®XT-TX(XLPO)insulation
Features:
Compliance to the European Normative for European Transit Customers
Class 5 stranded tinned copper in mm2 sizes
RoHS Compliant
Available Constructions:
EN 50306-2: Thin Wall, Single Core Unsheathed
EN 50306-3: Thin Wall, Single Core & Multi-Core Screen & Sheathed
EN 50306-4: Thin Wall, Multi-Core Unscreened and Sheathed (Class E and Class P)
EN 50306-4: Thin Wall, Multi-Core Screened and Sheathed (Class E and Class P)
EN 50264-3-1: Medium Wall, Single Core Sheathed or Unsheathed
EN 50264-3-2: Medium Wall, Multi-Core Unscreened and Sheathed
EN 50264-3-2: Medium Wall, Multi-Core Screened and Sheathed
EN 50382-2: Silicone Rubber, Single Core Unsheathed (120C or 150C ratings)
Product meeting the EMD specifications 179 & 304
179 Spec-Locomotive Insulated Wire, sizes #3 awg and smaller
-65C to 125C
Thermoset rubber polymer compound
304 Spec-Locomotive power Cable, sizes #1 awg and larger
-70C to 130C
Thermoset rubber polymer compound
Awaiting final testing validation, in process now
Estimated end of Q12013, a fully tested and compliant product
Features
Irradiated Cross-Linked Insulation System (XLPO)
Tinned copper braided shield designed for significant EMI/RFI reduction
Arctic-grade, heavy duty reinforced Neoprene jacket
Excellent Flame Retardance
Qualified to IEEE 1202, IEEE 383, & VW-1
Temperature range -45C to 100C
Compliant to AAR S-4210, AAR approved
Available in armored (aluminum or galvanized steel) or unarmored versions
Designed specifically for installation both under and between freight cars
8 AWG 37/24
XLPO
Tinnedcopper braid
Arctic-gradeNeoprene
NominalO.D. 0.725”
Category 5 Shielded Cable
Features:
Compliant to EIA/TIA-568-B.2 Patch standard’s Category 5,Tinned copper24awg 7/32strandPolyolefinallowing data transfers up to 100MHz
Aluminum/Polyestertape 100% coverage& tinned copperbraid 85% coverage
4 pairs, each pair twisted together
Each pair has a different lay length
Smoke opacity and density — ASTM E662Polyrad®XT
NominalO.D. 0.300”
Toxicity — BSS 7239
Flame-retardancy
Meets 49CFR Part 238 Appendix B for low voltage wire & cable
Designed specifically for transit vehicle applications
Meets FST Industry Standards
Features:
Irradiated Cross-Linked Insulation System
Outstanding Electrical Performance, Controlled Electricals
Qualified to VW-1
Outstanding Oil Resistance
Low Smoke, Low Toxicity
Qualified to ASTM E662, BSS 7239, & SMP 800-C
Available constructions (not limited to the below listings):
Polyrad® XT RG 59 Type Coaxial Cable
Polyrad® XT RG 59 Type Coaxial Cable + One Power Pair 18 AWG Data Cable
Polyrad® XT Two Conductor 16 AWG 100 OHM Shielded Data Cable
Polyrad® XT Two Conductor 18 AWG 120 OHM Shielded Data Cable
Polyrad® XT Three Conductor 18 AWG 120 OHM Shielded Data Cable
Polyrad® XT Two Pair 20 AWG 120 OHM Shielded Data Cable
Polyrad® XT Two Conductor 20 AWG 100 OHM Shielded Data Bus Cable
Polyrad® XT Two Conductor 20 AWG 120 OHM Shielded Data Bus Cable
Polyrad® XT Two Conductor 16 AWG 120 OHM Shielded Data Bus Cable
4/0 AWG5320/34rope barecopper
Features
TPE Insulation / Reinforced Neoprene Jacket
Class M conductor stranding, 5320/34 (4/0 awg) and 259/34 (3/C 10awg)
Normal operating temperature: -55C to 90˚C
Extreme temperature resistance during molding operation: 375˚F
Excellent flexibility (4/0 AWG 5320/34); withstands continuous vibrations
TPEinsulation
ReinforcedNeoprene
NominalO.D. 0.885”
Outstanding resistance to moisture, oils and fluids, abrasion, tearing,compression, ozone, sunlight, flame and heat
Compliant to Amtrak Specification: D-77-24; ASTM B3; ASTM B172;UL Standard 62; ICEA S-95-658/NEMA WC 70
Available in 4/0 1C and 10awg 3C constructions
The General Cable Transit Team
Kim Dout
Product Engineer
860-465-8789
Amy Gee
Product Manager /Business Team
859-572-8601 Office
859-760-8994 Mobile
Gary Caporizzo
North American Sales Manager - Transit
203-761-6627 Office
203-807-0385 Mobile
