Loc Performance Products, Inc. Company Overview & Applicable Products & Services April 2014

Contents 1. 2. 3.

Company Background Loc Engineering Production Capabilities • • • • • •

4. 5.

CNC Machining & CNC Turning Gear & Spline Hobbing, Shaping, Shaving, & Grinding Heat Treating Coatings Assembly Testing

Loc Advantages Closing Remarks

Company Background Full service provider of medium to large machined components and assemblies for drivetrain and suspension systems used in the defense, heavy truck, and heavy equipment industries •

Privately Owned: Founded by Victor Vojcek in 1971

•

Modern 265,000 square foot, state-of-the-art facility

•

Leading small business supplier to TACOM (U.S. Army Acquisition Office for ground vehicles)

•

First small business to receive a multi-year/multi-million dollar government contract

•

Specialties include vehicle suspension systems and driveline gearbox components and assemblies

Company Background Over 100 Machine Tools used to manufacture a wide variety of products requiring tough to machine materials Manufacturing Equipment • • • • • • • •

CNC Machining and Turning Centers CNC Hobbing, Shaping, and Gear Grinding CNC OD/ID Grinding CNC Wire EDM Induction Hardening and Tempering Welding and Fabrication Equipment Complete Tool Room Facility Well Equipped Inspection Facility including Non-Destructive Testing

Typical Materials • • • • • • •

Armor Steel Castings, Forgings, and Plate Stock Austempered Ductile Iron Castings Gray and Ductile Iron Castings Heat Treated Alloy Steel Stainless Steel Aluminum Titanium Castings and Forgings

Company Background Typical Products • • • • • • • •

Final Drive Gearbox Assemblies Road Arm Assemblies Suspension Housing Assemblies Wheel Hub Assemblies Engine Components Tie Rods Tow Bar Assemblies C.A.R.C. (Chemical Agent Resistant Coating)

Company Background Defense Platforms Supported • • • • • •

• • • •

• •

M88 Hercules Recovery Vehicle M1 Abrams Bradley Fighting Vehicle HMMWV FMTV Stryker MRAP Expeditionary Fighting Vehicle (EFV) M113 Armored Personnel Carrier M9 (ACE) Armored Combat Earthmover M109 Self-Propelled Howitzer AAVP7 Amphibious Assault Vehicle

Company Background Large Precision Machined Components Work Piece Size

Equipment

Milling

Ø72.8" x 61"

Toyoda FA1050

Turning

Ø70.9" x 59.1"

OM Ltd. Neoa-16EX

Turning

Ø39.1” x 90.6” Ø10.8” x 164”

Mori Seiki SL-603C/2000

OD/ID Gear Grinding

Ø25.5” x 43.3”

Niles ZE 630

Inspection

47.2” x 86.6” x 39.3”

Brown & Sharpe Global Advantage CMM

Equipment Used to Manufacture Large Generator and Transmission Components

Company Background Loc Customers

Quality System Credentials • • •

• • • • •

ISO/TS 16949:2009 / ISO 9001:2008 Certified AS 9100:2009, Rev. C / ISO 9001:2008 Certified Quality system complies with MIL-STD-45208 Use of SPC to control critical characteristics Full calibration system for gages and measurement devices adheres to MIL-STD-45662 1st piece set-up approval and operator in-process checks guarantee quality 100% product validation testing on assembled products Full wash system for all assembled components and finished parts that adheres to Millipore cleanliness specification

Quality System Credentials

Quality System Credentials Quality System Credentials

Loc Engineering Loc Product Development Process (LPDP)

Concept Design Phase

Preliminary Design Phase

The Loc Product Development Process (LPDP) allows Loc to provide the full spectrum of engineering services to its customers. LPDP is a gateway-based process that requires peer reviews, quality control checks, team member signoff, management signoff, and director level signoff prior to the completion of a development phase.

Production Launch Phase

Critical Design Phase

Production Sustainment

Design Verification Phase

Test Readiness Phase

With LPDP, all aspects of the product development life cycle baseline are controlled, archived, and in sync as changes occur throughout the process • Product Requirements • Requirements Compliance • Risk Management • Project Schedule • Solid Models • Drawings • Engineering Analyses • Bill of Material • Specifications • Test Plans

Loc Engineering Analysis Software ProEngineer FEA (ANSYS)

Fatigue Advisor Mechanism Dynamics

In - House Developed Design Analysis Tools LocGear

LocSpline

Focus Areas – Design Engineering 1. Gearbox Design • Final Drives for Tracked Vehicles • Wind Turbines • Hybrid Vehicle Drive Systems

• Geared Hub Drives for Wheeled Vehicles • Monorail Geared Drives • Oil & Gas Exploration

2. Gearbox Test Services • Functional • Temperature

• Reliability • Submergence

3. “Productization” of Emerging Designs • • • •

CAD Services Design for Manufacturability Cost Reduction Identification 3rd Party Functional Review Analysis

• GD&T • Specifications • Robustness Improvements • Life Analysis

Loc Engineering Loc has successfully executed several significant projects, many of which were previously attempted by larger organizations without success.

• • • • •

M1 Final Drive M88 Final Drive Planetary Speed Reducer Wind Turbine Generator JLTV Wheel Corner Assemblies

Loc’s management team has the training and successful track record of managing larger scale operations and projects.

Loc Engineering JLTV Wheel Corner Assemblies

In 2011, Loc Engineering conceptualized, designed, manufactured, tested, and delivered a superior wheel corner assembly with a planetary geared hub for the Joint Light Tactical Vehicle (JLTV) program.

The wheel corner design integrated the vehicle’s brake solution, Central Tire Inflation System (CTIS), geared final drive hub, and knuckle into a compact system.

Loc Engineering JLTV Wheel Corner Assemblies Within a 9 month period, Loc went through 2 design, build, and test phases that culminated in the delivery of several vehicle sets for Government vehicle testing. Concept Design Preliminary Design Critical Design Manufacturing – Initial Prototypes DV Testing - Initial Prototypes Critical Design –Performance Improvement* Manufacturing – Performance Improvement*

February 2011 March 2011 April 2011 July 2011 September 2011 September 2011 November 2011

* The performance improvement was associated with additional capability the customer required to add in Central Tire Inflation System (CTIS) functionality.

Loc Engineering Recent Award – Final Drive Phase II SBIR

Abstract Heavy add-on-armor installed on the Bradley Fighting Vehicle has degraded the vehicle’s mobility performance. Vehicle acceleration has declined to 80% of its original capability. To cost effectively modernize the mobility system, the final drive torque capacity must be significantly increased to maintain the current vehicle interfaces and packaging space. Loc Performance Products, Inc. (Loc) has developed its MaxTorQD technology in Phase I research that doubles torque capacity, improves efficiency, and provides a driveline Quick Disconnect solution that simplifies towing and maintenance operations. During Phase II, Loc proposes to test promising gear material, surface finish, and coating technologies identified in Phase I to physically quantify torque capacity and efficiency improvements. Loc will then apply knowledge gained through testing and further maturation of its Quick Disconnect technology to develop one vehicle set of the Bradley Modernization Final Drive for delivery at the end of Phase II. This drive will provide a Quick Disconnect function and contain sufficient torque capacity to meet the long term needs of both the Bradley and Paladin Integration Management (PIM) vehicle platforms.

This SBIR project is enabling Loc to offer optimized gear designs that balance weight, cost, and performance.

Loc Engineering Loc has the following test capabilities and assets for performing design and process validation testing. • Free Spin Torque Testing • Dynamometer Life Testing • Max Ambient Temperature Testing • Min Ambient Temperature Testing • Water Submergence/Air Decay Leak Testing • Gear Fatigue Testing (2014)

Loc is financially able and willing to add additional in-house capability as required to support new business.

Loc Engineering Free Spin Torque Testing

Utilized on every production geared assembly prior to shipment Also a valuable test for initial prototype builds for assessing performance

Loc Engineering Dynamometer Life Testing

• Wheeled Hub Test Stand • Four Square Test Stand For Tracked Vehicle Drives (as shown) • Full range of torque and speed operating conditions • Closed loop feedback control

Loc Engineering Extreme Ambient Temperature Testing

Temperature ranges from -70F to over 250F

Loc Engineering Measurement Capabilities • • • • • • • • • • •

Coordinate Measuring Machines (3 DCC Controlled – 1200mmX2200mmX1000mm) Roundness Tester (600mm Diameter) Gear Profile Measurement (600mm Diameter) Surface Roughness (multiple parameters) Hardness Testing Capabilities (Rockwell and Brinell) Optical Comparator Magnetic Particle Inspection Capabilities Cleanliness Testing Facilities Gage Calibration Lab (Complies with AIAG MSA) Various manual inspection equipment Paint thickness and adhesion testing

Production Capabilities Loc Performance Products, Inc. is vertically integrated, performing the majority of required manufacturing operations in house. • • • • • •

CNC Machining & CNC Turning Gear & Spline CNC Hobbing, CNC Shaping, Shaving, & CNC Grinding Heat Treating Coatings Assembly Testing (Covered in Loc Engineering Slides)

Loc is capable of providing any combination of the above

CNC Machining & CNC Turning QTY

3 AXIS VERTICAL MACHINING CENTERS

X

Y

Z

ADDITIONAL INFORMATION

2

ENSHU 650V

63"

26.6"

26"

FANUC 15M CONTROLS

3

ENSHU S400

25.6"

17.7"

18.1"

YASNAC J50 CONTROLS

4

ENSHU 650VX

62"

25.6"

26"

YASNAC 180M CONTROLS

6

ENSHU EV 650

63"

25.6"

25.9"

FANUC 16M CONTROLS

1

FADAL VMC 4020

40"

20"

20"

FADAL 88HS CONTROLS

3

FADAL VMC 6030 HT

30"

30"

21"

FADAL CNC 32MP CONTROLS

1

MORI MV - 40 M

31.5"

16.1"

20.1"

MSC 518 CONTROLS

QTY

4 AXIS HORIZONTAL MACHINING CENTERS

X

Y

Z

4

ENSHU 630H

35.4"

31.5"

29.5"

FANUC 16MA CONTROLS

4

ENSHU JE 40

15.7"

19.7"

15.7"

FANUC E40 CONTROLS

4

ENSHU JE 60

23.6"

23.6"

24.8"

YASNAC i80 CONTROLS

1

ENSHU JE80G

31.5"

31.5"

32.7"

FANUC i80 CONTROLS

1

MORI MH 633

39.4"

33.5"

36.2"

MSC-502 CONTROLS

1

TOYODA FA 1050

63"

55.1"

45.2"

GE FANUC 31i CONTROLS

4

MORI NH 4000 DCG

22"

22"

24.8"

MORI-SEIKI MG-501 CONTROLS

X

Y

Z

22"

15.5"

18"

QTY 2

3 AXIS HORIZONTAL MACHINING CENTERS ENSHU HMC 40

ADDITIONAL INFORMATION

ADDITIONAL INFORMATION FANUC 0M CONTROLS

CNC Machining & CNC Turning QTY

2 AXIS TURNING CENTERS

MAX DIA

Z TRAVEL

ADDITIONAL INFORMATION

3

FUJI ANW-41

11.8"

17.91"

ROBOTIC LOAD / FANUC 18i CONTROLS

5

MORI NL 3000/700

16.5"

32.2"

2 w/LIVE SPINDLE / MSX-850III CONTROLS

1

MORI SL 403/800

24.4"

39.2

MSC 501 CONTROLS

1

MORI SL 403B/800

24.4"

39.2"

MSC 501 CONTROLS

2

MORI SL 65/A

32.2"

33.9

FANUC 10T CONTROLS

3

MORI 75/A

34.6"

61"

MF-T4 CONTROLS

1

MORI SL 603B

35.4"

124"

FANUC CONTROLS

1

MORI SL-75B

29.9"

61"

FANUC 18T CONTROLS

3

MORI ZL-250/600

10.2"

25.6"

MSC 501 CONTROLS

2

MORI ZL-35B/750

15.3"

33.7"

MSC 518 CONTROLS

1

MORI ZT 2500 Y

14.6"

37.7"

LIVE SPINDLE / MSX 501III CONTROLS

1

SAMSUNG SL65-1000

35.43"

39.37"

1500RPM SPINDLE SPEED / FANUC Oi-T CONTROLS

QTY

3 AXIS TURNING CENTERS

MAX DIA

Z TRAVEL

ADDITIONAL INFORMATION

1

OM NEOA-16EX

78.75"

39.4"

LIVE SPINDLE / FANUC Oi-T CONTROLS

QTY

VERTICAL TURNING CENTERS

MAX DIA

TURNING HEIGHT

ADDITIONAL INFORMATION

2

HONOR SEIKI VL-66A

29.13"

25.59"

2000RPM SPINDLE SPEED / FANUC Oi-T CONTROLS

2

HWACHEON VT-550R

25.59"

27.56"

1500RPM SPINDLE SPEED / FANUC Oi-T CONTROLS

Component Manufacturing Flywheel Housings and Power Take Off Units

Component Manufacturing Turbocharger Components

CNC Gear & Spline Hobbing, Shaping, Shaving, Grinding, & Honing QTY

GEAR / SPLINE

DESCRIPTION

2

RED RING GCX-587

GEAR SHAVER

1

RED RING GCU-2804

GEAR SHAVER

1

FELLOWS No. 12

GEAR SHAPER

5

FELLOWS 20-4

GEAR SHAPER / 4 CNC, 1 AUTOMATIC

1

COLONIAL BROACHING MACHINE

BROACHING MACHINING

1

BARBER-COLMAN STANDARD

HOBBING MACHINE

2

MITSUBISHI GD30CNC

HOBBING MACHINE

1

KAPP NILES ZE 630

PROFILE INTERNAL/EXTERNAL GEAR GRINDER

1

TOYODA 45M

CYLINDRICAL GRINDER

QTY

HONING EQUIPMENT

DESCRIPTION

1

ENGIS 8

MULTI-SPLINE HONE

1

SUNNEN VSS-64

MULTI-SPLINE HONE

1

SUNNEN SV 1005

CNC MULTI SPLINE HONE

1

XLO MICROMATIC

VERTICAL HONE

Component Manufacturing Gear & Spline Capability

Heat Treating

In-House heat treat capabilities include induction hardening, quench, and tempering. The dual spindle CNC induction hardening machine can process parts up to 40 inches in length and up to 100 pounds in less than 4 minutes. The machine has the ability to selectively harden areas of a component while preserving the material properties as a whole

Loc has a 25+ year relationship with an outside heat treat supplier/partner who performs our gear carburization and hardening

Coating Loc Performance Paint Facility LocPac • Specializing in C.A.R.C. (Chemical Agent Resistance Coating) paint • Government approved C.A.R.C. paint source • LocPac provides epoxy, polyurethane, & enamel coatings in a multitude of colors • Capable of painting materials such as iron, aluminum, steel & titanium • Heavy duty paint lines with capacity for parts weighing up to 4,500 pounds • Extensive masking capabilities • All work controlled with pictorial work instructions • Custom packaging department

Manufacture New Assemblies Road Arm/Road Wheel Assemblies Pivot Arm & Idler Arm Assemblies Starting with the M60 battle tank in 1984, Loc has been providing road arm assemblies for the military’s fleet of tracked vehicles. Loc pioneered the process for refurbishing road arms at half the cost of new assemblies. Arm assemblies provided by Loc since 1984 • • • • • • • •

40,000 for Abrams 10,000 for M88 12,000 for Bradley 8,000 for M9 ACE 6,000 for M109 6,000 for AAVP7 10,000 for M60/M48 15,000 for M113

Manufacture New Assemblies Quality Track Record: Final Drive Assemblies Loc is the leading provider of new final drive assemblies for the U.S. military’s fleet of combat tracked vehicles. These assemblies are geared drive systems that include planetary gears, offset gears, and combinations thereof. Each of these is designed to handle extreme torque loading and high radial loading due to track tension and other external loads. New final drives provided since 1990 • • • • • • •

9,000 for Abrams (Planetary) 3,500 for M88 (Planetary with Braking System) 1,450 for Bradley (Offset) 1,500 for M9 ACE (Planetary with Offset) 900 for M109 (Offset) 300 for AAV (Offset) 80 for EFV (Offset)

Over 22 years without a single manufacturing return

Manufacture New Assemblies Superior Performance – M1 Abrams Final Drive • • • •

•

Top reliability concern for the M1 Abrams at production launch Original manufacturer outsourced critical component manufacturing Loc won a contract to manufacture these planetary drives directly for the Army Loc analyzed failure modes and developed a robust manufacturing plan to address the known failures that were occurring in the field. Working within constraints of the original design, Loc has provided drives since 1991 with no issues.

Manufacture New Assemblies Superior Performance – Abrams Final Drive •

• • •

Saved over $100M in sustainment costs by tripling final drive life and eliminating the need for lubricant change intervals At launch, Loc fully resolved customer issues of leak/gear failures Supplied over 9,000 units to date with no late deliveries and no failures Loc renews the contract every 3 years by being low bidder and has provided each drive for the last 22 years

Loc’s 1st Approach is to Establish Robust Manufacturing Methods

Manufacture New Assemblies Superior Performance – Hybrid Bus Geared Drive •

Like the M1 Drive, the incumbent manufacturer had a sub-par quality record

•

Customer validation testing is extremely positive for Loc’s manufactured assembly Ramping into production now in support of new vehicle builds and field replacement of incumbent manufactured assemblies Working with customer to provide further enhancements

•

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Loc Advantages • • • • • • • • • • •

Financial Strength and Stability Competitive Pricing On-Time Delivery Responsive to Customer Needs Small Lot Specialists In-House Design Engineering In-House Prototype and Production Capabilities Experts in Advanced Geared Systems Vertically Integrated Manufacturing Advanced Assembly Experience Product Validation and Testing

Closing Remarks Loc benefits from a solid reputation for engineering and manufacturing components and complex mechanical assemblies. Target products are: • • • • •

Gearbox Assemblies – Both New and Remanufactured Road Arm / Road Wheel Assemblies Suspension Housings Track Shoes Other Large Machined Components

Loc is adding new business due to its competitive cost structure, delivery rating, product quality, and exceptional customer support. We are currently 50% defense and 50% commercial.

Thank You

Wayne Dula Loc Performance Products, Inc. Director of Business Development (734) 927-3819 [email protected]