MFG Corporate Presentation October 2009 NXPowerLite

8/14/2019 MFG Corporate Presentation October 2009 NXPowerLite

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Molded Fiber GlassCompanies

Molding the future through focused diversity

Founded 1948


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Family Owned since 1948

60 Years of Dedicated Composites Manufacturing

Senior Management Team with Over 500 Years ofComposites Experience

15 Entities in NAFTA

2.0 Million Square Feet

2,000 Teammates

Strong Balance Sheet

Corporate History andOverview


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History

1948 Premier Molding Ashtabula, OH

1952 Tray Company Linesville, PA

1955 Union City Union City, PA

1956 Research Company Ashtabula, OH

1962 Construction Products Union City, PA

1979 Composite Systems Ashtabula, OH

1985 West Adelanto, CA

1994 North Carolina Morganton, NC

1995 Northwest Stevenson, WA1997 Texas Gainesville, TX

1998 Water Treatment Products Union City, PA

1999 Kansas Independence, KS

2003 Galileo Reno, NV

2005 Alabama Opp, AL

2006 Design Center Portland, OR

2007 Mexico Monterrey2008 Wind Energy Services Sweetwater, TX

2008 South Dakota Aberdeen, SD

2009 Wind Energy Services Independence, KS

2009 Wind Energy Services - Worthington, MN

Growth

History


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Two Watershed Events1953 Corvette

MFG began production of all

the body panels for the

Corvette.

Continuous Corvette

supplier including the

present C6 Model

Robert S. Morrison

Corvette Hall of Fame

1955 MFG Boat During a slow period inplant sales, MFGprototyped and built the firstfiberglass boats on themarket. When no other boatbuilder had faith in FRP,MFG started their owncompany.


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1950s

1949 Wonder bread trays 1954 Chevrolet Corvette 1955 FRP Boats

1961 Truck Liners 1967 Hoppers 1968 Gamefisher Boats

1960s


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1982 Bob Evans Fascia 1980s New Holland 1980s Kenworth

1980s

1990s Freightliner1996 MiraVista Shakes1990s Weinermobile

1990s

1971 Washington DC Subway 1976 Costa Mesa 1977 Outboard Motors

1970s


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2003 Shipboard Radome

2005 Antennas 2005 Personal Watercraft

2001 34.5m blade 2002 Avalanche

2000 and Beyond

2006 Corvette Z06 2006 Nissan 2007 MRAP

2004 Bridge Beams
http://www.mustee.com/durabase/rectangle.shtml


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http://www.mustee.com/durabase/rectangle.shtml


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MFGBusiness Segments

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Proprietary Water Treatment

Construction

Military/Government

Anti-Ballistics Communications

Trays/Pans/Boxes

Fume Hoods

Flat Sheet

Wind

33%

Truck

20%

OEM

16%

Auto14%

Military

5%Proprietary

12%


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Corporate wide Composites ExpertiseCorporate wide Composites Expertise

MANUFACTURING PROCESSES

Hand Layup

Sprayup

Robotic Gel Coating

Advanced Preform Process

Vacuum Infusion

Vacuum Bag Molding Resin Transfer Molding Lite

SMC, LMC, CMC , BMC Compression

Molding

In Mold Coating (IMC)

Bonding, Assembly and sequencing

Robotic Routing and Water Jet

Finishing

Paint Capabilities

Sandwich Core Composite Molding

RAW MATERIALS Matrix

Thermoset

DCPD (Metton)

Polyester

Vinylester Epoxy

Phenolic

Thermoplastic

LFT

Reinforcement Glass fiber

Carbon fiber

Aramid

Sandwich Core

Materials


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Automation / Robotics PressLoad/Unload

Preform

Resin Pour

Waterjet

MFG EnablingTechnologies

Hydraulic PressCapacity

CSC - 21 Presses

75 to 3,000 Tons PMC - 22 Presses

113 to 1,500 Tons

Tray - 24 Presses113 to 750 Tons

NC - 4 Presses1,000 to 3,000 Tons

Research - 3 pressesup to 2,000 Tons

De Mexico - 2 presses

MFG CompressionMolding


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Program Management

Program Management per QS9000 / TS16949 Core Team(s) assigned - dedicated Program Manager

Advanced Product Quality Planning (APQP) Product Design and Development

Participate in Design FMEA

Feasibility Reviews and Documentation

Flow Diagrams

Process Design and Development

Control Plans, FMEA, Instructions and layouts

Product and Process Validation PPAP

Project Timelines and review meetings

Document Task Matrixes and responsibilities Interface with TMP to capture plant needs

CATIA, Unigraphics and IGES Support


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MFG - Three Initiatives

Lean SixOperationalExcellence

SparkPlugSales Growth &

Diversity

PioneerTechnological

Leadership

Research & Development

Materials

Processes

Applications

Commercialization

Sales / Marketing Benefits

Operational Improvements

Decentralized sales structuresupporting the diversity of MFG

Identifies synergy among MFGEntities

Leverages Lean 6 / Pioneeractivities to develop new products

and markets

Dedicated Corporate Champion & Staff

Management Educated in Lean and Six Sigma at All Entities

Green & Black Belt Certification Program

SENIORLEADER

MANAGERS(SLM)

MFG NC


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MFG NC (North Carolina)

In mold coating

Robotic WaterJet trimming

Robotic Adhesive Dispense

Robotic Routering

Part sequence control

Interior trim

Heavy Truck FocusAPP robotic Preforming

Robotic resin dispense

Compression molding

SMC

LCM

MFG de MexicoTransportation and Lighting

MFG TRAYProprietary storage devices

QS 9000 Registered ISO 14001 RegisteredFreightliner Certified AIAG Affiliated

CFA Affiliated

Processes

Robotic Preforming (APP)Robotic Resin Dispense

SMC Compounding

In Mold Coating

Compression Molding

SMC / LCM

Robotic Water Jet Routering

Prime and Topcoat Painting

Bonding and Part Assembly

MFG CSC(Composite Systems Co.)


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Processes

Open Molding

Robotic gel coating

Robotic water jet

Vacuum Infusion

Prime Painting

Bonding and Assembly

MFG UC (Union City)Heavy Truck and Custom Products

Concrete Forms

MFG CP (Construction Products)

Waffle Slab

Forms

Beam, Slab

Forms, Long

Forms

Round Column

Forms

Custom Forms

Special Shapes

MFG WTPWater Treatment Products

MFG GalileoRadomes and Antennas


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Vacuum Infusion

Resin Transfer Molding (RTM)

Hand Layup

Sprayup

MFG TexasWind Energy

MFG WestWind Energy and Custom

MFG Alabama

Wind Energy

MFG South DakotaWind Energy


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MFG WES Wind Energy Service MFG WES Wind EnergyServiceIndependence, KS Sweetwater, TX.

MFG WESWorthington, MN

Wind EnergyService
http://www.autocomposites.org/index.cfmhttp://www.awea.org/http://www.lawea.org/


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Certifications

A2LA

ISO/IEC 17025

Freightliner

General Motors

Composite Testing

Mechanical Properties

Physical Properties

Bond Strengths

Paint Adhesion

Residual Styrene

Analytical

Gas

Chromatograph

Burnouts

SurfaceContamination

The MFG Design Center providesvarious levels of design engineeringsupport to MFG Entities andCustomers.

MFG Design Center MFG Research

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Anti-Ballistic Panels

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Military

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Alternative Energy

Wind Energy

Solar Energy

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Infrastructure

Water Treatment

ConstructionWaffle Slab Forms

Beam, SlabForms, Long

Forms

Round Column

Forms

Custom Forms

Special Shapes

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Communications

Radomes

Antennas

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Rail Transportation

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Features & Benefits of SMC Compression Molding Sheet Molding Compound (SMC)- a Molding Compound Consisting of a B-staged Resin and Chopped

Glass Fiber, Used in Compression Molding.Utilizes coupled flow of chopped glass and resin resulting in consistent fiber content throughout the part.

Pre-combined glass fibers flow easily for facilitation of more complex parts. Parts which could feature

Ribs, Bosses, Molded in Studs.

Hydraulic Press utilized in

Compression Molding.

Mold Fully Closed- Material Flowsand Fills Tool, Producing Part.

Cutting and Bundling Charge SMC Charge in Female Die

Molded SMC Shower Base

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SMC ProductionSMC Production

Best-in-ClassBest-in-Class

Industry benchmarking

MFG CSC Ashtabula OH

MFG Premier Ashtabula OH

MFG Linesville PAMFG Morganton NC

CSP Conneaut OH

IDI Noblesville IN

Budd Van Wert OH

Meridian Jackson OH

Supplier participation

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SMC ProductionSMC Production

Best-in-ClassBest-in-Class

Processing upgrades

Capacity expansion

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Some Applications in SMC

Fiberglass residential door skins

Residential shower, sink, bath components

Underground Transformer Boxes

Truck body components

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Features & Benefits of LCM Compression MoldingWorld leader

Liquid Composite Molding- a Closed Mold, Usually of Steel, Used to Form a Composite

Under Heat and Pressure.

Utilizes Positive Placed Glass pre-form resulting in greater control of fiber orientation.

Allows design tailoring to give additional strength to specific areas of a part.

Screen created in part

shape with perforated metal

Binder and glass roving

chopped to desired lengths

and blown toward screen

Vacuum behind screen

draws and disperses

glass into part shape

Oven cures preform

and is removed fromscreen

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Features & Benefits of LCM Compression MoldingWorld leader

Lower molding pressure required than with SMC.

Produces lower density part versus SMC given identical part thickness.

Superior surface quality to SMC

Mix applied

to preform

Resin and

fillers combined

on site to

create mixPreform with mix

and veil

(if needed) areplaced on mold

Press applies

pressure to push

mix through glass

and cure

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Some Applications in LCM Heavy Truck body panels

Automobile Rear Compartment

Safety Helmets

Transit Seating

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Secondary Assembly Operations

Value Add processes Robotic Machining

Water Jet Fabrication

Drill fixtures

Peening

Bond of parts

Hand apply

Robotic bond

Hardware addition

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Research and Development

Materials Industry standard materials

Cutting edge developments

Weight reduction case studies Process

Selection guidelines

Design education for engineers

DFMA

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Developed a process to exfoliate nanoclay filler in SMC and LCM paste Conducted production scale compounding and molding trials Test results confirm the following benefits:

- increased physical properties over standard SMC and LCM

- specific gravity reduction by 20% without glass microspheres

- enhanced pigmentation and appearance

- enhanced rheological behavior, improved mold flow properties

Nanoclay SMC and LCM

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High-Temperature Resistant

Laminate Epoxy based composites with Tg > 200 C ( 400 F )

Polyester based composite with Tg > 375 C ( 700 F )

Application is lead free solder pallet for the PCB market

65 70 % glass content = extremely high physical properties

Close tolerance molding for flatness : 4 ft. X 8 ft. panel X 8 mm

thickness molding held to +/- 0.010 flatness, final surface

machining to a flatness of +/- 0.003

Comparison of Tan Delta Rochling, Norplex Micarta, & MFG Epoxy Materials

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

0.18

0.2

0.22

0.24

0.26

0.28

0.3

0.32

0.34

0.36

0.38

0.4

0.42

0 1 5 30 4 5 6 0 75 9 0 105 12 0 1 35 15 0 1 65 18 0 1 95 2 10 2 25 2 40 2 55 2 70 285 3 00 31 5 3 30 34 5 3 60 37 5 3 90 40 5 4 20

Temperature Degree C

Tan

Delta

RoschlingTanDeltaSample1 Cycle2



WavMax 7000Black TanDeltaSample1 Cycle2

WavMax 7000Black TanDeltaSample2 Cycle2

WAV06TanDeltaSample1Cycle2



MFGNon-Epoxy SystemRochling Epoxy

MFG Epoxy WAV

WavMax 7000 Black

MFG Non-Epoxy

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PP Honeycomb /

Fiber Glass TP Skins

Developed a thermocompression process to fuse glass fiber

reinforced polypropylene skins to a polypropylene honeycomb

core

Benefits include :

- ultra-lightweight laminate ( specific gravity = 0.235 g/cc )- high stiffness to weight ratio

- high impact and damage resistance

- impervious to water and other environmental contaminants

Target market is the food handling industry

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UV Stable SMC

SMC formulations have been developed and tested that exhibit< 30% loss in 60 degree gloss and < 1.0 delta E color changeafter 1000 hours QUV bulb A exposure; goal of 2000 hours isachievable

Evaluating a black pigmented, low-profile, automotive SMC at35 and 50% glass content that has demonstrated NO change in

60 degree gloss or appearance after 4000 hours of Xenon arcexposure and 4 years of south Florida and Arizona test siteexposure

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Cored Phenolic Skin

Laminates Composites based on end grain balsa cores or syntactic foam

with glass fiber reinforced phenolic skins

Composites based on phenolic resin impregnated Parabeamfiber glass

Defined benefits :

- high stiffness to weight ratio- high resistance to fire environment

ASTM E-162-02a flame spread < 5

- low smoke and toxicityASTM E-662 optical smoke density < 40

Target market is mass transit flooring

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Pigmented BC / CC IMC

Development Dual path development project with Sherwin-Williams and

OMNOVA

Successful pigmented BC IMC trials conducted at MFG/NC on

M2 Hood and Undercab Cover

Demonstrated successful pigmented BC IMC repair process

S-W Approach : BC IMC with CC hand pour applied

OMVONA Approach : BC IMC with CC IMC, initiated a 1 year

process development project to define a robust process

MFG believes that IMC of BC and CC is feasible and only

realistic approach to pigmented IMC

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Carbon Fiber Laminates MFG continues to manufacture and mold standard density and

low density CF molding compound for Corvette applications :

- low density CFMC wheelhouse outer panel

- standard density skins on balsa cores for the floorboards

Supply of CF is tight ; cost of CF is escalating

Seeking new sources of CF to assure supply and stabilizepricing

Investigating a new wet slurry process for the preparation of CF

preforms for LCM molding based upon papermaking process

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Ballistic and Blast Resistant

Laminates Continuing development in high glass content ballistic resistant

laminates for vehicle armoring, architectural uses, and blastresistant applications

Laminates capable of meeting UL 752 Level 3 ballisticperformance have been demonstrated at 0.50 thickness and5.0 lbs/ft2 areal density

As a component of a complex, multi-material armoring system,structure has demonstrated the ability to contain multiple hitsfrom a 50 caliber API round at 2750 ft/sec velocity

Producing a blast mitigating footware device for defeating theharmful personal effects of land mine detonations

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MFG West Coast Design Center


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MFG West Coast Design CenterValue by Design The MFG Design Center based in Portland, Oregon provides various

levels of design engineering support to MFG Entities and Customers.

Design Drives Process!

Process Drives Cost!

Optimization of Design and Process Through DFMA

Delivers Higher Quality Products and Reduces Overall

Investment!

CATIA V4 & V5 Cad Systems

(Advanced Solid/Surface Design & Detail)

Data Conversion for IGS, STP, DXF etc..

Online Web-Design reviews

(Go-To-Meeting)

Reverse Engineering Projects

DFMA (Design for Manufacture and Assembly)

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Draft Angles

Over Sized Routed-Out Openings

Molded-In Features

Shear-Edge Design

Minimum Radii

Part Nestability for Shipping

Check Fixture Requirements

Die-Pull Studies, Block Studies

Bond Gaps, Stops & Overlaps

Holes & Slots- Molded, Drilled

Mold Scribes (Advantages)

Ribs, Bosses & Inserts

Material Thickness &Transitions

GD&T and Process Capability

Tooling Impact (Engineering Changes)

MFG-DFMA SMC/LCM Design Buy-Off

(Design features that require DFMA optimization)

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MFG Research

Established 1956

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40 Testing Accreditations

Mechanical, physical, environmental,flammability, electrical and chemical properties

Thermal analysis FTIR (Fourier TransForm Infrared

Spectrometer)

Dielectric analysis

Optical microscopy

In-house, professional engineers

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MFG Research

A 60-year Track Record of Breakthrough R&D and Problem Solving At MFG,

technology improvement is an integral part of our business model. MFG Research is

the largest and best-equipped laboratory in the composite processing industry. It's

purpose is to provide MFG entities with accurate, fast-response technical and

laboratory support. This dedicated resource enables MFG to help customers improve

their products by leveraging the intrinsic characteristics of molded fiber glass

technology to improve performance, appearance, durability, electrical and/or

mechanical properties, development time cycle, as well as cost.

The close working relationship between MFG Research and the MFG entities has

resulted in the development of many advanced material formulations and processes,

including our Automated Preform Process (APP) that elevates preform technologyinto a new level of process superiority.

MFG Research is certified via A2LA as an accredited laboratory per ISO/IEC 17025,

which includes 40 testing accreditations.

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Markets


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MFGBusiness Segments

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Markets Electrical

Business Machines

Agriculture

Seating Water Treatment

Construction

Lighting

Wind Energy

Rail Truck

Specialty Automotive

Aerospace

Military/Government

Marine Recreation

Communications

Residential

Trays/Pans/Boxes

P r o p r i1 3 %

T r u

2 1

O E

1 7

W i

3 4

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MFG Corporate Presentation October 2009 NXPowerLite

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