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Headquarters
Bosal International NV
Dellestraat 20
3560 Lummen
Belgium
Tel: +32 (0)13 - 53 08 00
Fax: +32 (0)13 - 53 14 11
Website: www.bosal.com
Email: [email protected]
Europe
Bosal International NV
Dellestraat 20
3560 Lummen
Belgium
Tel: +32 (0)13 - 53 08 00
Fax: +32 (0)13 - 53 14 11
Africa
Bosal Afrika (Pty) Ltd
Box 1652
Pretoria 0001
Rooibok Avenue
Koedoespoort Ind. Sites
Republic of South Africa
Tel: +27 (0)12 - 391 1000
Fax: +27 (0)12 - 333 7872
.ORTH!MERICA
Bosal International North America
1476 Seaver Way
Ypsilanti, Mich 48197
U.S.A.
Tel: +1 734 - 547 7000
Fax: +1 734 - 547 2988
South America
Bosal International South America
Rua Ptolomeu 344
Sao Paulo-Sp
CEP 04762-040
Brazil
Tel: +55 (0)11 - 55 22 99 55
Fax: +55 (0)11 - 56 86 63 69
Asia
Bosal International Shanghai Rep. Office
A65, 11/F,
Shanghai Mart
2299 Yanan Road West
Shanghai 200336
P.R. China
Tel: +86 - 21 - 6236 7081
Fax: +86 - 21 - 6236 7081
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3UPERVISORY"OARD
The Board is pleased to report that the Bosal Group has achieved significant
positive progress throughout the 2007 financial year, due in part to the continuous
growth into new and expanding markets. In Europe for example, Bosal is establishing a strong foundation in the former Eastern Bloc countries.
In Hungary, the construction of a new
16,000 m² plant next to the existing
Bosal Autoflex plant has been completed.
The new plant will produce jacks, wind
stops, machined parts and housings for
detachable and retractable towbars.
In Russia, 244,000 m² of land has been
acquired in the new automotive industry
supplier park near Kaluga. OEM production
of exhausts for Renault/Dacia has already
begun in leased premises there, along the
lines of a similar project delivered by Bosal
Fouman Pars in Iran.
In Zaporozhye, Ukraine, the joint venture
with ZAZ is exceeding expectations with
production output well ahead of plan.
The Bosal-Oris joint venture is rapidly
increasing production volumes using the
global Bosal manufacturing infrastructure.
New production sites have been established
in Mexico, USA and Hungary.
In Europe Bosal Oris has won a
significant number of new OEM contracts
for their retractable towbar as has the
growing roofbars and roofracks operation.
Their wind deflector product range has also
consolidated its market-leading position
world-wide.
In 2007 two major new manufacturing
sites came into service:
Unique customer solutions for heavy
duty exhaust systems contributed to the
success of the truck, bus and industrial
(TBI) division. The cabin manufacturing
operation in Denmark had another record
year with several exciting new contracts.
Plans are being developed to extend its
production capacity using Bosal’s global
manufacturing footprint.
With the successful entry into new and
developing markets around the globe
and strong performances in established
markets, the Bosal Group Board is
optimistic and foresees further growth in the
various product market combinations that
will reinforce Bosal’s market leadership.
Dr h.c. Karel Bos (1928)
Chairman
Karel Bos (1961)
CEO
In Turkey, the newly built Bosal Mimaysan
plant in Pelitli combines in one state of the
art facility the operations of two separate
plants in Gebze and Kartel and will as a
result deliver significant synergies. The
transfer of production to the new plant
went without a hitch, recognized by the
fact that Bosal Mimaysan was voted Best
Supplier of 2007 by the Turkish Automotive
Industry.
Economies of scale were also achieved in
the USA where the R&D facilities in Ann
Arbor (MI) and the production plant in
Warren (MI) were combined into one brand
new 17,000 m² facility in Ypsilanti (MI).
The new technical center is significantly
larger and features improved development
facilities to service new and existing OE
customers.
Facts and figures Bosal Group
Chris Dewulf
Dr h.c. Karel Bos (1928)
2
BOSAL 2008
Automotive Division
Industrial Division
4URNOVERINEMILLION
Turnover in 2007: E 158 million
)NVESTMENTSINEMILLION
0LANTS
$ISTRIBUTION
(EADCOUNT
Investments in 2007: E 4 million
Plants: 5
Karel Bos (1961)
Headcount: 869
BOSAL 2008
3
Dr Danie van der Walt
(Research & Development Director Bosal
International, South Africa)
“Our research and development activities are
focused on the establishment of new technologies
for manufacturing cost-effective products that deliver
future customer needs.”
Research & development
Innovation is a key driver throughout the various R & D organizations
within the Bosal Group. The drive for innovation pushes the boundaries
in materials, packaging, weight-saving and emission reductions, while
cost efficiency remains a major driver for the customer.
The exhaust system has developed into a complex product in its own right.
It combines several functions such as the control of emissions, temperature
management, noise signature management, sound level reduction and
vibration isolation. Through the global spread of R & D facilities Bosal is able
to bring global programs to their points of use and deliver customer needs for
a greater range of products and technologies.
Hot high frequency endurance testing of a close coupled catalytic converter assembly.
Ir. Rudi Valgaeren
(Program Director Bosal International, Belgium)
“Our commitment is to develop dedicated
competitive technical solutions for different markets
in order to further reduce exhaust gas emissions of
petrol and diesel engines.”
4
BOSAL 2008
BOSAL 2008
5
Manfred Nowak
(Group OE Sales Director)
“Global presence has always been a
competitive edge for Bosal. We strengthened
this advantage by opening new plants in Russia,
Iran and Hungary. In the coming years we will
continue and intensify our efforts to grow in the
emerging markets.”
John Miles
(President Bosal North America)
“During 2007 we successfully
moved into our new facilities
in Ypsilanti Michigan and
Queretaro Mexico. These new
facilities are designed to operate
with world class efficiencies and
quality standards and incorporate lean
manufacturing principles.”
OE Exhaust systems for passenger cars
Bosal is a major worldwide supplier to the auto industry of complete
exhaust systems including fabricated insulated manifolds and catalytic
converters. Bosal recently developed and started supplying an exhaust
system that is more cost effective, lighter and more durable than the
previous generation of exhaust systems.
6
BOSAL 2008
BOSAL 2008
7
Rob Sweetnam
(Group Commercial Director AM Europe)
“We are totally committed to meeting the
ever-changing demands of our aftermarket
customers throughout Europe by supplying
the highest quality exhaust, catalytic converter
and towbar products in a professional,
cost-effective and efficient manner.”
Exhaust systems - Aftermarket
By exploiting its OE competencies in the aftermarket, Bosal exhaust systems
meet the most stringent standards and guarantee a life expectancy in line with
customer needs. The vertical integration of the various business processes
ensures specific expertise and know-how of all aspects of the product design,
production and distribution processes. Innovative and responsive logistics
are being enhanced and supported with e-business solutions resulting in an
unrivalled availability to serve the aftermarket customer base.
8
BOSAL 2008
BOSAL 2008
9
Paul Hiel
(Managing Director TBI Europe)
“Bosal’s expertise and
know-how in emission
technology is a competitive
advantage in the TBI sector.”
9.70e+02
9.49e+02
9.29e+02
9.09e+02
8.88e+02
8.68e+02
8.48e+02
8.28e+02
8.07e+02
7.87e+02
7.67e+02
7.46e+02
7.26e+02
7.06e+02
6.85e+02
6.65e+02
6.45e+02
6.25e+02
6.04e+02
5.84e+02
5.64e+02
High temperature heat exchangers
Combined Heat and Power systems (CHP), for both domestic and industrial
applications, is a fast growing market. The concept delivers energy savings,
better utilization of non-renewable energy resources and emissions reduction.
Bosal is developing and manufacturing high temperature components such
as pre-heaters for Stirling engines, recuperators for micro turbines and heat
exchangers and natural gas reformers for fuel cells.
Dr Ir. Jean-Paul Janssens
(Advanced Research and Bosal Energy Conversion Director)
“Recuperation of heat at high temperatures is a technology that grows in importance
every day. Over the years Bosal has invested in the research, development and
manufacturing of components for energy systems which has resulted in a variety of
product lines. In this way, a unique core competence has been established on which
we base our strategic program for energy savings and emission reduction.”
10
BOSAL 2008
Truck, Bus and Industrial
Bosal exploits its leading expertise in the automotive
sector to develop and manufacture silencers and
diesel exhaust gas after-treatment systems for Trucks,
Buses and Industrial applications. TBI exhaust systems
are tailor-made to OE specifications in Belgium and
the United Kingdom and the customer base extends
to manufacturers of stationary equipment, agricultural
machinery, off-road and construction machinery.
Bosal’s strong market share in this sector is based
on lengthy experience and a strong understanding of
the unique requirements and operating environments
of the wide range of potential applications.
BOSAL 2008
11
Jörg Riehle
(Managing Director ACS/OEM Division)
“It is our mission to improve the
value offering to our customers by
continuously inventing new products
and processes.”
AK 41
The ultimate detachable towbar system
with a high D-value for heavy duty towing or
a lower D-value for daily use.
Automotive carrier systems
Towbar systems
The Bosal Oris joint venture has further strengthened its market leading
position in Europe, capitalizing fully on the combined strengths of innovation,
world class manufacturing and customer service. Bosal Oris delivers the full
AK 11
spectrum of towbars from the most innovative discreet systems to
straightforward durable designs.
Retractable towbar
The ORIS MATIC retractable towbar is a cutting-edge, patented, retractable
design that eliminates the need to detach any parts of the unit when not in use.
The innovative system has an external operating mechanism located under the
bumper, which, like the towbar itself, is entirely hidden from view when not in
use. The towbar swivels behind the bumper in approximately two seconds
once the mechanism is operated.
M11
In close cooperation with automobile manufacturers,
Bosal Oris has developed a range of high specification
detachable and fixed towbars for OE applications.
Retractable towbar M5
12
BOSAL 2008
BOSAL 2008
13
U Preston, United Kingdom
U Dublin, Ireland
U Lyon, France
U Reims, France
U Mitry Mory, France
U Paris, France
U Béthune, France
U Lummen, Belgium
U Oevel, Belgium
Bosal worldwide 2008
U Ypsilanti, MI, USA
U Indianapolis, IN, USA
U Lavonia, GA, USA
U Querétaro, Mexico
U Vianen, Netherlands
U Made, Netherlands
U Randers, Denmark
U Sorø, Denmark
U Prague, Czech Republic
U Zaragoza, Spain
U Madrid, Spain
U Sagunto, Spain
U Hannover, Germany
U Viersen, Germany
U Markgröningen, Germany
U Mannheim, Germany
U Sachsen, Germany
U Łódz, Poland
U Kozuchow, Poland
U Zaporozhye, Ukraine
U Kaluga, Russia
U Moscow, Russia
U Novoorsk, Russia
U Cegléd, Hungary
U Kecskemét, Hungary
U Cortubi, Pitesti, Romania
U Bursa, Turkey
U Pelitli, Turkey
U Gebze, Turkey
U Kingston, Canada
U Acton, MA, USA
U Whippany, NJ, USA
U Tuyauto,
Casablanca, Morocco
U Umo, Medellin, Columbia
U São Paulo, Brazil
U Gravatai, Brazil
U Córdoba, Argentina
Bosal R&D
Bosal Manufacturing Plants
Bosal Distribution
Bosal Licensing Partners
Bosal DongWon Licensing Partner
U Teheran, Iran
U Andisan, Uzbekistan
U Sharda, Nashik, India
U Pune, India
U Shanghai, China
U Yantal, China
U Liu Zhoi, China
U Haman, Korea
U Asan, Korea
U Rayong, Thailand
U Hanoi, Vietnam
U Tokyo, Japan
U Bulawayo, Zimbabwe
U Pretoria, South Africa
U Pretoria, South Africa
U Durban, South Africa
U Cape Town, South Africa
U Port Elizabeth, South Africa
Bosal OE Sales & Engineering Office
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BOSAL 2008
BOSAL 2008
15
T Manufacturing
NEurope
NBenelux
NTurkey
NGermany
NFrance
NGreat Britain
NSpain
NBB Plant 6
NBNL Plant 8
NBTB Plant 34
NBMT Plant 11
NBMT Plant 12 (SILS)
BOM Plant 62
NBOS Plant 63
NBF Plant 17
NBTM Plant 33
NBLR Plant 39
NBUK Plant 21
NBES Plant 47
BIZ Plant 54
Belgium - Oevel - 68,300 m2
The Netherlands - Vianen - 14,500 m2
The Netherlands - Made - 17,669 m2
Turkey - Pelitli - 19,000 m2
Turkey - Bursa - 4,000 m2
Germany - Markgröningen - 16,500 m2
Germany - Sachsen - 21,000 m2
To be extended in 2008.
France - Béthune - 36,200 m2
France - Mitry Mory - 4,400 m2
France - Reims - 17,665 m2
Great Britain - Preston - 45,600 m2
Spain - Sagunto - 21,500 m2
Spain - Zaragoza - 8,000 m2
NMiddle East
NAfrica
NCzech Republic
NDenmark
NHungary
NUkraine
NIran
NSouth Africa
NBCR Plant 45
NBSI Plant 53
NBAF Plant 31
NBTF Plant 57
NBOH Plant 42
NBSH Plant 42A
NBAR Plant 28
NBRUS Plant 20 (School plant)
NBZAZ Plant 60
NBFP Plant 41
NBA Plant 1
NBA Plant 2
NBA Plant 3
Czech Republic - Prague - 22,800 m2
To be extended in 2008.
Denmark - Randers - 20,000 m2
To be extended in 2008.
Hungary - Kecskemét - 6,375 m2
Hungary - Cegléd - 2,416 m2
Hungary - Kecskemét - 10,304 m2
Hungary - Kecskemét - 6,265 m2
Russia - Novoorsk - 2,300 m2
Russia - Kaluga - 4,000 m2
Ukraine - Zaporozhye - 4,000 m2
Iran - Teheran - 3,500 m2
South Africa - Pretoria - 45,800 m2
South Africa - Port Elizabeth - 2,000 m2
South Africa - Pretoria - 26,700 m2
NRussia
NNorth America
NSouth America
NZimbabwe
NCanada
NUnited States
NMexico
NArgentina
NBrazil
NBA Plant 9
NBA Plant 10
NBCA Plant 5
NBC Plant 7
NBIMI Plant 65
NBIGA Plant 51
NBMX Plant 25
NBOX Plant 66
NBARG Plant 26
NBDB Plant 50
NBDB Plant 50
NBDB Plant 58 (SILS)
South Africa - Pretoria - 18,000 m2
South Africa - Pretoria - 20,000 m2
South Africa - Pretoria - 2,100 m2
Zimbabwe - Bulawayo - 7,500 m2
Canada - Kingston - 19,000 m2
United States - Ypsilanti, Michigan 16,700 m2
United States - Lavonia, Georgia 11,893 m2
Mexico - Querétaro - 6,400 m2
Mexico - Querétaro - 2,000 m2
Argentina - Jesús María, Córdoba 1,400 m2
Brazil - São Paulo - 6,230 m2
Brazil - Sao Paulo - 15,800 m2
Construction of new plant opening in 2008.
Brazil - Gravatai - 700 m2
Poland
Denmark
Ireland
Germany
United States
BP Plant 16
BDK Plant 22
BEI Plant 27
BD Plant 36
BUS Plant 38
Poland - Lódz´ - 1,200 m2
Denmark - Sorø - 5,200 m2
Ireland - Dublin - 2,050 m2
Germany - Viersen - 15,600 m2
United States - Whippany, New Jersey 7,300 m2
Representative offices
T Research & development
Belgium
United States
South Africa
Turkey
T
NBA Plant 4
NEurope
Russia - Moscow
NAsia China - Shanghai, Japan - Tokyo
Germany
T Distribution
The Bosal network 2008
BI Bosal International - Plant 48
Belgium - Lummen - 11,000 m2
BINA Bosal International
North America - Plant 65A
BA Bosal International
South Africa - Plant 1A
BMT Bosal International
Turkey - Plant 29
BOM Bosal International
Germany - Plant 62A
United States - Ypsilanti, Michigan 2,000 m2
South Africa - Pretoria - 1,300 m2
Turkey - Gebze - 600 m2
Germany - Markgröningen - 16,500 m2
AK6
The ultimate Bosal detachable
system that is almost invisible after
removal. The socket plate rotates
and is hidden behind the bumper.
The towball can be attached and
detached quickly and easily.
Ecofit
The Ecofit is the
economical detachable towbar concept.
It combines reliability
and ease of mounting with
excellent value for money.
Ecofit is the detachable
solution for every motorist.
Standard
bolt-on
The towball is
integral with the
car and cannot be
removed without tools.
It uses a tried and tested
design of the highest standard.
Automotive carrier systems
Towbar systems
As motorists increasingly seek to maximize the versatility of their cars for
practical or leisure activities, so the appeal of towbars is increasing. Bosal
provides solutions for all market sub-sectors, including heavy duty pick-ups,
family hatchbacks and upmarket luxury SUVs.
ORIS MATIC
Welded
The towball is welded to the
subframe and is therefore not
removable. The towbar is
designed to fit perfectly and
fulfils every task flawlessly.
The high quality finish
ensures the towbar will
last throughout a long and
demanding lifetime.
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BOSAL 2008
Flange ball
This towbar is suitable for heavyduty towing and is therefore
ideal for commercial and
off-road vehicles. The
design is compatible
with two- and fourhole fixings (height
adjustable) depending
on the vehicle type.
The retractable towbar that eliminates
the need to detach any parts of the unit
and is invisible when not in use.
BOSAL 2008
17
Vilson Codato
(Managing Director South America)
“We are determined to support our OEM
customers around the globe by providing effective
services and innovative solutions to meet their
specific needs in their global markets.”
Jacks and toolkits
Bosal has held global market leadership in the OE supply of jacks and toolkits
for many years. Jacks are produced in a wide variety of designs, sizes and
lifting capacities, and include scissor and cantilever types. Complete solutions
are delivered to customer assembly lines in the form of toolkits of which the
jack forms an integral part.
Wind deflector
Bosal Oris manufactures a highly successful range of wind deflectors for
convertible cars. These OEM products, called WINDSTOP, reduce the air
turbulence and noise level for occupants when driving with the hood down.
As a result, wind deflectors are becoming an automatic choice for buyers of
these cars as they improve driver and passenger comfort and extend the
‘hood down’ driving season.
18
BOSAL 2008
BOSAL 2008
19
Roofbar
Roofrack
Roof carrier systems
Kinematics
Bosal designs and produces roofbars for delivery to production lines of
OEMs for factory fitment. The roofbars are designed to enhance the styling
cues of the specific models. Bosal engineers the roofbars to ensure that
durability, practicality and safety are incorporated into the designs in addition
to their aesthetic appeal. Bosal also produces a wide OE range of roofracks
for commercial vehicles. Bosal Oris designs and produces a range of OE
accessories for SUV’s like side rails with and without steps, running boards,
grillguards and bullbars for non European applications. Kinematics is a
successful OE product line especially for convertible cars with hardtop.
Running board
Bullbar for non
European applications
20
BOSAL 2008
Side rails with steps
BOSAL 2008
21
Carsten Fruergaard
(Managing Director BSI)
“Our global customer base
requires customized cab solutions
which we can deliver with our
dedicated design capability.”
Vehicle cabs
Bosal Sekura, headquartered in Denmark, designs and
produces vehicle cabs. These are supplied to leading
manufacturers of agricultural and industrial vehicles
throughout the world. In order to keep up with market
demand the production capacity of Bosal Sekura
Industries will be increased.
The construction of a brand new 15,000 m2 production
plant is planned to be ready before the end of this year.
Further more the Bosal Global manufacturing footprint
will be fully exploited with the employment of Bosal UK
and Bosal Industry Georgia in the USA.
Warehouse racking
Bosal’s Netherlands-based warehouse racking division develops tailored
solutions to complex storage problems. Initially supplying to the
automotive industry, it has extended its customer base to the wider
general warehousing and logistics sectors.
22
BOSAL 2008
BOSAL 2008
23
Luc Vints
(Managing Director Tube Europe)
“We will further differentiate ourselves in the
competitive market of welded precision tubes
through our manufacturing knowledge and
technical capabilities. We create extra value for
our customers through our logistics solutions and
by offering semi-finished tube products.”
Tubes and precision tubing
Bosal has a global footprint in the delivery of tubes and tubular products, with
manufacturing facilities in Belgium, South Africa and the United Kingdom. The
products range from round, oval, square and perforated to complex profiles
and vary from low carbon steel in hot rolled, cold reduced to coated steel
aluminized and galvanized to stainless steel ferritic and austenitic. Bosal’s
production facilities incorporate the latest hi-tech computer-controlled tube
mills which process more than 120,000 tons of steel per year.
Agricultural irrigation
Pierre Hough
(Managing Director South Africa)
Based in South Africa, “Bosal’s House
of Irrigation” supplies a diverse customer
base around the world. It produces aboveground sprinkler irrigation equipment and
also manufactures a wide range of “quick
coupling” irrigation pipes in either galvanized
lightweight steel or aluminum.
24
BOSAL 2008
“By optimizing every stage of our
integrated value chain, we continue
to increase our competitiveness
in the local market as well as
reinforcing our strong position as an
export company.”
BOSAL 2008
25
Michel Geerts
(Group Human Resources Director)
“Bosal remains committed to
investing in its employees and in
managing the group according to
strong core family values.”
The Board of Directors
from left to right:
Dirk Dessers (COO),
Bosal do Brazil’s new
Karel Bos (1961, CEO),
15,800 m2 plant is under
Joop van Boesschoten (CFO).
construction and will be
ready in 2008.
Forecast
The global automotive industry continues to demonstrate significant improvement,
with the emergence of new markets and new brands as well as the ever-increasing
focus on reducing carbon emissions and the introduction of sustainable technologies.
In the Ukraine it is planned to build on the
scale. An additional focus in the years
production of exhaust systems by starting
ahead will be on heat recuperators for
to manufacture tubes, consistent with the
automotive applications.
Group’s policy of vertical integration.
The after-treatment of exhaust gasses
To maximize the world-wide opportunities
the 22,500 m² plant by almost 50%
Recognizing the increasing diversity
for commercial vehicles and heavy duty
for Bosal’s extensive range of products,
(10,600 m²) within the next 12 months.
of vehicle models, production of wind
industrial applications is yet another major
deflector systems and towbars will be
area of investment for the coming year
started up in the USA.
in terms of product development and
the Bosal Group Board is planning further
expansion into new and developing
This global building program is all part of
markets. In addition the Bosal Group will
a major three-year investment plan which
continue to invest in those markets where
started in 2007 with the acquisition of
Turning to environmental issues, Bosal
it is already established.
more than 750,000 m² of land in the USA,
continues to invest in the development
Finally, recognizing that it is the people that
Russia, Hungary, Brazil and Turkey.
of high-temperature heat exchangers in
make the business, Bosal continues to
low-emissions technology applications
invest in tailor-made education programs
In 2008 the building of a brand new
durability testing.
manufacturing facility will be started in
Bosal Sekura Industries, the successful
such as combined heat and power (CHP)
to facilitate promotion from within the
Kaluga, Russia. Bosal has acquired a
vehicle cabin manufacturing operation
systems. For high efficiency technology
organization. Throughout a committed
total of 244,000 m² of land.
based in Denmark, recently won a
applications Bosal is developing fuel
workforce, Bosal remains a united family
number of significant new contracts.
reformers for high temperature fuel cells
with shared values and goals.
Another manufacturing facility under
To meet demand, production capacity
to generate electricity on a megawatt
construction is a 15,800 m² plant in
will be further increased by exploiting
Itupeva, Brazil. The new facility will allow
the current Bosal global manufacturing
the Group to expand its market-leading
footprint, specifically the production
range of jacks and toolkits with new
facilities of Bosal UK and Bosal
product lines.
Industries Georgia. To accommodate
Bosal Sekura Industries 100,000 m2
With production at Bosal Czech Republic
land has been bought in Denmark. The
already running near capacity, increasing
construction of a new 15,000 m2 plant
market demand and the addition of new
will be completed before the end of
OEM contracts will be met by extending
this year.
Bosal’s global management team: one aim, one goal!
26
BOSAL 2008
BOSAL 2008
27