The Aluminum Advantage for the Global Automotive Industry
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1 The Aluminum Advantage for the Global Automotive Industry Todd Summe Global Technology Director, Automotive October 8, 2013
2 Novelis is the Global Industry Leader in Aluminum Sheet Global Aluminum Leader in: Flat Rolled Products Automotive BiW Sheet Recycling Global Operations: 25 Plants 9 Countries 11,000 Employees 2
3 Novelis Footprint Uniquely Serves Global Customers Existing Plant Existing Plant: Brownfield Expansion New Plant: Greenfield Expansion 3
4 Novelis Automotive Göttingen, Germany Nachterstedt, Germany Sierre, Switzerland Changzhou, China AUTOMOTIVE FINISHING LINE 4
5 Novelis Automotive AUTOMOTIVE SHEET PRODUCTION Göttingen, Germany Nachterstedt, Germany Changzhou, China Sierre, Switzerland AUTOMOTIVE FINISHING LINE 5
6 Novelis Automotive Kingston, Ontario AUTOMOTIVE SHEET PRODUCTION Oswego, New York 2 New Automotive Finishing Lines 6
7 Global Automotive Aluminum Sheet Demand 2,000 1,800 1,600 1,400 1,200 1,000 Demand Projection (in ktonnes) 1,216 CAGR: 13% 1,952 Asia N. American CAGR: 37% Europe Source: Novelis internal Global Automotive Demand (Status: June, 2012) Explosive growth in North America. Tripling demand in Europe. Asia still evolving. 7
8 Legislation Trends g/km Auto CO 2 Emission Trend Lower Global Trend (g/km of CO2) USA China 2008: : : : : USA China Korea Korea 2008: : Japan Brazil EU EU 2008: : : Source: International Council on Clean Transportation (ICCT) Japan 2007: : 125 8
9 Miles Per Gallon Legislation Trends g/km Auto CO 2 Emission Trend U.S. Light Vehicle Unadjusted Fuel Economy (Actual MPG is 15% to 20% Lower) Japan USA China Korea Since the 1980 s we have sacrificed increased fuel economy for more size, more comfort, more safety and more horsepower. The goal is to keep EU all these gains while we nearly double fuel economy Source: International Council on Clean Transportation (ICCT) Lower Global Trend (g/km of CO2) USA China Korea EU Japan 2008: : : 172 Inovar (Brazil) According to the decree, the 2008: 185 average 2015: 167 vehicles of the regime s beneficiaries commercialized from 2017, will 2008: 198 have to consume 12.08% 2015: 150 less fuel than nowadays. - Brazilian Ministry of Development, 2008: 154 Industry and International Commerce 2015: : : : 125 9
10 Lightweighting is Key % weight loss +5-7% fuel savings 10
11 Aluminum Automotive Applications Today Airbag Housing Roof Body Structure Trunklids Hoods Brake Housing Bumper Beams Heat Exchangers Body Skin Sheet Suspension Components Wheels Wiring Fenders Doors Up to 40% weight reduction! Source: EAA / Novelis 11
12 Cost / MPG MPG Improvement Aluminum-based Mass Reduction Provides Cost Effectve Fuel Economy National Academy of Science Fuel Economy Technology Assessment 2011 $ ,00 $1.000 MPG Improvement 8,00 7,00 $800 6,00 $600 Cost / MPG 5,00 4,00 $400 3,00 $200 2,00 1,00 $0 0,00 Source: US Aluminum Association 12
13 Global Automotive Strategy Novelis is committed to extend our leadership position in: via investment in a unique global production footprint via investment in Global Research and Development via investment in breakthrough recycled content 13
14 Global Production Investments USA Oswego 240kt Heat treatment Germany Nachterstedt 400kt Recycling capacity China Changzhou Heat treatment line with 120kt Brazil Pinda 200kt Hot/cold rolling & Recycling expansion Germany Norf New Recycling center with 50kt capacity Korea Yeongiu & Ulsan 400kt Rolling & Recycling capacity expansion 14
15 Global Research & Technology Goettingan, Germany Global R&T NE Plant Support Product Development Spokane, WA Global MMP Global Plant Support Mumbai, India ABSTC R&D Technology Dev. Modeling Kennesaw, GA Global R&D Global Engineering Global Manufacturing Excellence Global Quality and Safety Pilot Scale Development Pinda, Brazil SA Tech Support NSA Plant Support Product Development Sierre, Switzerland Global R&T NE Plant Support Product Development Ulsan, Korea Global R&T NA Tech. Support NA Plant Support Product Develop. 15
16 Sustainability - New Study Finds Aluminum Better than Steel to Save Energy and Cut Carbon In September 2013, a new U.S Department of Energy study found that: Reducing vehicle weight with aluminum can result in the lowest total vehicle lifecycle environmental impact An aluminum-intensive vehicle can achieve up to a 32% reduction in total lifecycle energy consumption, and up to a 29% reduction in CO 2 emissions 16
17 The 80% Commitment 100% Energy Greenhouse Gases 100% Primary Aluminum Recycled Aluminum 5% 5% 17
18 The 80% Commitment 100% Energy Greenhouse Gases 100% 80% GOAL Primary Aluminum Recycled Aluminum 80% by % in % 39% in % by % 18
19 The 80% Commitment 80% GOAL 80% by % in % 43% in 2012 in % by
20 Novelis Global Sustainability Approach Novelis will increase its current use of recycled aluminum to 80% by 2020 This will remove 10 million metric tons of greenhouse gas emissions from the aluminum product value chain annually. 20
21 Closed Loop System 21
22 Key Enablers ALLOY SEGREGATION 6xxx Lo Cu 6xxx Novelis % Outer Skin Scrap 90 ROBUST ALLOYS STANDARDIZED SPECIFICATIONS Competitor 6xxx 100% Outer Skin Scrap Customer Process Scrap Hi Cu 6xxx Lo Mg 5xxx , 6005C xxx Hi Mg 5xxx Multi-purpose alloys = Good = Bad
23 Benefits of the Closed Loop Model 23
24 Global Products and Service
25 The Range Rover L405 Example! The world s first SUV with a lightweight aluminum body Source: Bad Nauheim Eurocarbody
26 Novelis Global Products Skin Inner Strength Crash Global Alloy Products 5754 Ac-170 / 6005C Ac-300 PX, T61 Ac-600 / 6451 Lube / Oils Hot Melt AlubVS Pretreatments & Lubricants Global PT (Under Devel) PT2/3 Structural PreTreatment M-TiZr - Gardobond AlubVS DOS M-P404 RP4107 E1 SX39 AL070 Quaker DC2 90 GLOBAL SPECIALTY/REGIONAL 26
27 Market Trends & Development Overview
28 Primary Global Market Needs in the Next 5 Years EUROPE Agressive competition Market growth Very high demand on novelty USA Exploding demand ; High volume programs High pressure on standardization & quality Agressive lightweighting, safety & durability CHINA Standards transferred from Europe and USA Manage import and grow domestic supply Full customer and application support BRAZIL Likely import intensive initially Assess business case for local products Full customer and application support 28
29 Systematic Management of Development Directions Segregation Melting Casting Strength & Hemming Recycling Fusion Process Optimization Strength & Crash Surface & Joining (Incl. steel-alum.) Forming & Welding 29
30 Development Focus Areas Strength / Hemming Forming Crash / Strength Ac-600 / 6451 Low Temp Paint Bake PB 300 MPa Ac-200 HF 5xxx Ac-200 RW Ac-600 RW Ac-300 T61 Ac-600 Crash 6xxx Cu free 300 Mpa 7xxx semi crash Surface & Joining Process Recycling Global standard pretreatment Pretreatment for mixed body Remote weldable 6xxx Fusion Casting Homogenization Hot and Cold Rolling Solution Heat Treating 6xxx skin and structural 5xxx structural 30
31 Key Takeaways Establish a strong global partnership for supply and collaboration Establish a commitment to standard global products and specifications Proactively address issues critical for effective adoption 31
32
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