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The ABC Group of Companies
Today’s automotive industry looks increasingly to external suppliers to provide more of
their components and product systems, and to deliver them, pre-assembled or ready to
install, exactly when and where they are needed. Behind each of these products is a
total customer solution — from design and development through to testing and
validation — that the customer expects the supplier not only to provide but to fully
manage, on their behalf. Our ability to meet and exceed this expectation and our longstanding record of design innovation, timely and economical prototyping, and
manufacturing excellence have made the ABC Group of Companies one of the world’s
leading automotive plastics manufacturers.
Building on the strength of a diverse, fully integrated resource base that covers
every facet of plastic processing technologies, we have produced a constantly growing
number of unique automotive components and product systems. The ABC Group
attributes much of its success to its investments in research and development. We
continue to invest significantly in all facets of research and development, including
material compounding, tooling and machine design, and particularly in our pursuit of
the infinite possibilities that can be achieved through advanced processing technologies.
These resources, together with our global manufacturing capabilities, have enabled the
ABC Group to establish a competitive, parallel relationship with the automotive industry
throughout the world.
Welcome to the ABC Group of Companies: a global supplier of automotive systems
Helga Schmidt
President and CEO
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Bydgoszoz, Poland
Ningbo City, China
A Global Perspective
Since its formation in 1974, the ABC Group of Companies has expanded to include more than thirty
facilities on four continents. Located in close proximity to our customers, these facilities are also
supported by sales, engineering and design personnel who can respond quickly to customer needs
and provide the organization with timely, accurate feedback. ABC Group’s manufacturing capability
has also evolved dramatically: from the production of individual components to the design,
production and assembly of complete systems and modules.
Each of the ABC Group’s facilities is supported by the ABC Group Tech Center, which provides
comprehensive research and development, engineering, rapid prototyping, testing, and advanced
technology services. Strategic business and financial planning, as well as administrative services, are
supported by the ABC Group corporate head office. Sound management policies and financial
strength enable the ABC Group to sustain continuous investments in new plant, equipment and R&D
initiatives.
In addition to our international automotive operations, the ABC Group also supplies packaging,
commercial and industrial markets worldwide.
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A global supplier of automotive systems
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System
Integration
The ABC Group’s reputation for product
innovation is internationally recognized. We
produce an extensive range of interior,
exterior, fuel systems and engine support
systems, and our product development
teams introduce new assemblies and
systems on a continuing basis.
We work closely with our customers
from the initial design stage to identify costsaving opportunities by adding further
value to the products we make. We have
developed innovative ways to improve the
quality of our products from concept to
production. As a result, we can provide the
customer with many competitive
advantages that are unique to our blow
molding, injection molding and other
process technologies:
• faster tooling development
• math data-based, in-house tooling
• competitive tooling costs
• rapid prototyping
• product design
• accommodating engineering changes
• more efficient use of vehicle space
• reduced component weight
• simplified assembly operations
• competitive systems cost
• materials selection expertise
Blow Molding
Injection Molding
Continuous
Extrusion
Interior Painting
Exterior Painting
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Engine Support
Systems
Air Management Systems: Complete systems,
including air cleaner housings, air intake ducts, expansion
chambers and multiple resonators. Designed to meet
performance requirements for air flow, NVH (Noise,
Vibration, Harshness), filtration, temperature and durability.
Proprietary technology allows previously separate vehicle
systems to be integrated as one, such as air cleaner
housing/washer reservoir assembly, for improved system
performance and integrity as well as reduced system costs.
Integrated Air & Fluid
Management System
Fluid Management Systems: Featuring unique
design to maximize limited space, and utilizing advanced
secondary operations. Systems include integrated washer
reservoir/resonator systems, windshield washer reservoirs,
brake fluid reservoirs and coolant recovery/pressure surge
tanks.
Flexible Products: Boots, bellows and seals, developed
using a unique processing method introduced by the ABC
Group. These products are internationally acclaimed for
their superior tensile and tear strength, and unmatched
temperature, chemical and puncture resistance. Ongoing
improvements to both the material and processing method,
made in collaboration with the material supplier and the
customer, have resulted in the development of a lighter
product with a longer life-span.
Windshield Washer Reservoir
CVJ Boots and Flexible Products
Air Management System
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ABC Group offers full product development support from
design and rapid prototyping to full pre and post production
analysis and testing.
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Fuel Systems
As part of our commitment to providing maximum
value and service to our customers, the ABC Group
offers a comprehensive range of blow molded fuel
management systems. Fuel tank and fuel transfer
systems provide highly durable construction, greater
space utilization and improved corrosion resistance.
Using co-extrusion and injection-molded
technologies, together with our industry-leading
product development know-how, we offer a range of
innovative technological and design-based customer
solutions. As one example, ABC Group uses a
proprietary blow molding process for filler pipe systems
that enables a reduction in the number of components
required, while at the same time providing improved
product quality such as fuel filler pipes with molded in
tabs, and featuring multi-layer construction and
electrical conductivity.
Multi-layer
Fuel Filler Pipe
Multi-layer tanks are produced and delivered as a
complete product system.
Our goal is to add further value to the systems and
components we produce. Our multi-process capabilities
enable us to produce several different components,
and also incorporate the secondary assemblies to
deliver products to our customers that are ready for
final installation in their vehicles. By designing and
building most of our own assembly equipment and
automated systems, we provide our customers the
assurance of a highly efficient, single source solution.
Conductive Multi-layer
Fuel Filler Pipe
Unique multi-layer fuel tank systems from a world leader
in blow molding based manufacturing. ABC Group offers
innovative, propriety technologies and broad expertise in
mono-layer, multi-layer and other extrusion processing
methods.
This welding and finishing assembly is a key element for providing a fully integrated customer solution. One of ABC
Group's core strengths is our ability to reduce the number, weight and cost of components without compromising the
overall system's integrity, quality or functionality.ality.
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Exterior Systems
Spoilers:
Offering significant design flexibility,
lightweight spoilers, which can incorporate lighting, are
molded and painted in an integrated operation. In addition
to design and engineering support, ABC Group produces
spoilers and many other large injection and blow molded
products, complete with painting and assembly, within a
single integrated facility.
Sunvisor
Running Boards: Structural blow molded systems
designed to meet customers’ structural and loading
requirements; available with Class A finish as accent color
or body color. Key benefits include increased design
flexibility and a reduction in the number of components
required.
Spoiler
Bumper Systems: Features include Class A paintable
exterior finish with integrally molded beam design to
reduce post-assembly; light weight with excellent energy
management, exceeding OEM impact standards, especially
at low temperature.
Exterior Trim: Black box, gray box design. Including
wheel flares and body trim featuring a Class A finish,
optimal design and engineering flexibility.
ABC Group’s Exterior Systems facilities feature complete
product-to-paint-to-assembly integration. The ABC Group’s
manufacturing facilities can accommodate any product
size or volume requirements, dedicating a single machine,
a production line, or an entire facility to meet their
customers’ needs.
Running Board
Spoiler with Light
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Blow Molded
Bumper Systems
Heavy Truck Bumper
Bumper Beam
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Interior Systems
Instrument Panels:
HVAC Distribution Systems:
Including complete IP assemblies, sub-assemblies and
components. We produce injection-molded Class A
surface IPs as well as injection-molded IP substrates
with foam, either with a vacuum-formed or powder
slush skin, all to comply with styling and manufacturing
requirements. Components can be integrated within a
single panel system to reduce the number of
components, thus providing both improved quality
and performance, as well as competitive tooling and
assembly costs. Single component blow molded panels
combine structural substrate, HVAC ducts and Class A
surface finish, all as a single unit. The following subassemblies comply with performance and quality
requirements, and can be supplied in any combination,
including completed, fully assembled systems:
Air bag door: ABC Group manufactures a range of
skinned and foamed-over substrate air bag doors, as
well as one-piece injection molded design in the latest
available materials.
Knee bolsters: Award-winning blow molded
assemblies offer enhanced dynamic impact
performance and greater design flexibility, and feature
matching grain, texture and color, GDT tolerancing,
and molded in fastening points.
Innovative systems include injection/blow molded
defroster ducts; HVAC ducts integrated into instrument
panels; dual zone HVAC control rear seat heater ducts;
defrosters and cross-car duct assemblies; and combined
cross-car and defroster systems.
At ABC Interior Systems Inc; products
are injection & blow molded, painted,
and assembled at a single facility. ABC
Group uses waterborne interior 1K and
2K paint systems and features soft
touch capabilities.
Instrument Panels.
Interior Trim:
Cargo Management Systems:
A full range of products, including injection molded
trims and covers; over-injection molded pull handles,
color and texture-matched skinned and foamed
armrests and consoles, blow molded panels and trims,
and low pressure in-mold decorating components.
ABC Group delivers systems, which surpass
performance requirements in the marketplace. Our
in-house design, technical capability and multiple
process experience offer end customers value added
features while meeting cost-targets.
Close-out Panel Assembly.
Seating Systems:
Unique blow molded seating systems offer consistent
quality, lower volume of foam, reduced weight, and
significant savings in program development, tooling
and piece costs. Increased design flexibility can reduce
the number of components in assembly, thus lowering
costs on completed seat assemblies and simplifying the
assembly operation.
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Vertical Integration
Product innovation can be achieved at several stages
of the manufacturing process and is often the result of
new combinations of design, materials, tooling and
processing technologies. Our expertise through each
of these represents the ABC Group’s greatest strength.
To our customers, the resulting benefits include faster
development time, increased design flexibility,
improved manufacturing and assembly efficiencies,
significant potential cost savings and enhanced
product quality and performance.
Machine Building:
Comprehensive custom design-build capability,
including secondary finishing equipment and extensive
automation and robotics capabilities.
Materials:
Extensive experience with all high performance
engineered resins, plus a range of proprietary resins,
recycled materials and reinforced thermoplastic alloys.
World-class polymer development and production
facilities are available co-jointly with design,
engineering and fabrication resources.
Manufacturing:
Design and Engineering:
Complete R&D and product development services and
capabilities, including Electronic Data Interface,
testing and full scale-up capabilities.
Tooling:
Fully-integrated CAD/CAM-based mold design and
fabrication, as well as traditional pattern-making,
model-making and cast tooling capabilities.
Facilities on four continents can accommodate
products of any size or production volume.
Painting:
ABC Group has extensive system assembly
capabilities. Fully articulating robots are used to
achieve optimum flexibility, efficiency and product
quality.
We conduct impact testing in our environmental
chamber, one of the largest of its kind in Canada.
We meet and test to specifications of the Federal
Motor Vehicle Safety Standard (FMVSS) and
Economic Commission for Europe (ECE).
Fully robotic interior and exterior paint lines deliver
consistent high quality finish, film build and
appearance.
Quality Assurance:
QA programs meet or exceed industry standards and
customer expectations.
To ensure compatibility with our customers’ systems, ABC’s design group supports a complete range of software and
operating platforms: I-DEAS, CATIA, Unigraphics, Autocad and Cadkey.
ABC Group's Exterior Systems feature complete
product-to-paint-to assembly integration.
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ABC Group's Interior Systems feature a fully
robotic interior paint line. Products are molded,
painted and assembled at a single facility.
To reduce development time, we use Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) capabilities.
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Materials
Salflex Polymers Ltd. coordinates the planning
and supply of proprietary and externally sourced
materials used by the ABC Group and other
manufacturers. This QS 9000 registered facility works
closely with our Research and Development facilities
on custom polymer blends and alloys for new product
development projects.
The quality of the materials we use is as important to
processing as it is to end-use product performance.
Achieving the precise combination of characteristics
and properties in the polymer is critical to effective
tooling and machine performance, and is also a vital
link in the development of better processing methods,
optimized manufacturing efficiencies and innovative
new products.
Performance of materials is
determined using tensile strength
testing, among others, from the
development phase through to quality
assurance.
The Salflex Polymers Ltd. lab has the
capability to perform physical and
chemical tests for verification of current
custom compounds or characterization
products under development.
Unique compounds from Salflex
Polymers Ltd. allow molders to meet
specialized automotive needs.
As one of the world's largest plastic processors, the
ABC Group has played a major role in the
advancement of thermoplastics and custom
compounds for specialized automotive products, as
well as for many unique industrial and packaging
applications. The ABC Group has extensive experience
with all high performance engineered resins, and
works closely with resin manufacturers to test and
evaluate new materials. Through our materials division,
Salflex Polymers Ltd., we have developed a range of
proprietary compounds, a family of thermoplastic
elastomers, a variety of recycled materials, and a line
of reinforced thermoplastic alloys (glass, mica-filled,
etc.) that serve as an effective, competitive alternative
t o
b o t h
m e t a l s
a n d
engineered plastics.
Multi-layer sheet extrusion capability at Polyform
Engineered Products, (a division of Salflex Polymers Ltd.),
is used to create unique applications for thermoforming.
One specific example is our capability to produce TPO sheet
up to 1,950 mm wide.
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Tooling and
Process Technology
The ABC Group’s greatest overall distinction is our
ability to constantly find new ways to replace
traditional materials and production methods with
blow molded components offering superior quality,
performance and value. With our unique blow
molding technology and resources, we have achieved
unprecedented levels of product capability, complexity,
size and sophistication.
Our focus on customer solutions has also taken
us beyond blow molding, to include other processing
methods, and new combinations of assembly
techniques and secondary operations. At the ABC
Group Tech Center, our design and engineering teams
deliver a complete product solution. One of our key
distinctions is the ability not only to design the product
itself, but also working in tandem with the Supreme
Tooling Group to design the tooling, machines and all
related finishing and secondary assembly systems to
meet that product’s exact requirements. R&D resources
include on-site blow molding and injection molding
machines and other processing systems, used for trial
molding and experimental, prototype and production
trials.
Our engineering capabilities include gray box and
black box design and testing. Tech Center engineers
work at a client location or project specific basis, and
maintain direct liaison with their OEM customers or with
their colleagues at other ABC Group locations worldwide.
•Rapid prototyping: from conceptual design, modeling and pattern-making to scale-up (to pilot and production), testing and analysis. •Centralized Cost Administration, for fast, accurate costing and quotations.
•CAD/CAM-based mold design and manufacturing for all processes.
•Design and assembly of molding machines.
•Design and manufacture of secondary finishing equipment, robotics and automation systems.
The ABC Group’s tooling facilities include advanced
machine building capabilities, providing fully integrated
design-molding-processing systems, tailored to the
specialized needs of every product in each of our
manufacturing plants worldwide.
We design and build automation systems and finishing
fixtures to streamline the manufacturing process.
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ABC Group’s Supreme Tooling Group uses
stereolithography technology to reduce lead time and
tooling costs. Stereolithography reduces prototyping to a
fraction of the time required in conventional methods,
providing an exact visual reference and an accurate
simulation of product performance and tooling guidelines.
The ABC Tech Center works in close unison with the
Supreme Tooling Group to support our operations
worldwide, providing comprehensive, fully integrated
R&D, design, engineering, prototyping,
testing, and advanced technology services.
The ABC Group’s Supreme Tooling Group, an ISO 90012000 registered facility, is a pioneer in the development
of specialized machines and tooling technologies for the
manufacture of blow molded automotive systems. With
our staff of design, engineering and technical specialists
and a full complement of advanced technological
resources, the ABC Group today remains an undisputed
industry leader.
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The ABC Group’s manufacturing base has evolved
towards increasingly larger machines, larger processing
facilities and the production of sizeable, more
sophisticated components and systems.
Manufacturing
The ABC Group operates more than 30 manufacturing
Blow Molding: Innovative, proprietary technologies
facilities, strategically located throughout the world, to
to meet diverse needs and applications in mono-layer,
provide direct support and services in close proximity
multi-layer and other co-extrusion processing
to our international customers. Designed primarily to
techniques.
meet customer and product-specific production and
Injection Molding: Advanced injection molding
assembly needs, these facilities provide maximum
technologies are used in the production of substrates
flexibility, efficiency, and responsive just-in-time
and multi-component assemblies.
delivery. Our automotive EDI is fully integrated with
Thermoforming/Sheet Extrusion: Applications
our order entry and manufacturing system.
include flexible skins for instrument panels and other
Each plant operates independently, offering
interior components; multi-layer door surfaces; under-
comprehensive resources and capabilities that can be
vehicle shields for splash and air management; and
dedicated and custom-tailored to meet specialized
large interior panels.
customer needs and opportunities. Local managers
Polyurethane Foaming: Accommodating a full
and engineers work in close collaboration with the
range of interior components.
ABC Group Tech Center’s corporate-based, cross-
Rotational Molding: A unique molding
functional engineering and product development
technology for specialized product requirements.
teams. Based on customers’ individual product
Continuous Extrusion: The high-capacity
requirements and priorities, the ABC Group’s
synchronized systems accommodate a variety of rigid
manufacturing facilities can provide a variety of
and flexible product applications.
processing capabilities:
ABC Group Thermoforming
computerized rotary machines have the
capability to produce parts as large as
nine feet by six feet. All machines are
equipped with twin heaters, zone
control ceramic elements.
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Fully robotic Interior paint lines
deliver consistent high quality finish
and appearance.
ABC Group combines innovative
co-extrusion and robotics
technologies to accommodate multistage processing and in-mold
assemblies, dramatically reducing
cycle time in the production of fuel
tank systems and other complex,
large-scale products.
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Quality Assurance
The concept of proactive quality management has
In the production process, quality assurance remains
been fundamental to the ABC Group’s philosophy
an integral and ongoing responsibility of all plant
since the company began operation. Our goal to
employees, each of whom participate regularly in
achieve and enhance customer satisfaction is reflected
quality-related training programs, seminars and
in our zero defect policy and in our overall, corporate-
workshops. We have also achieved significant quality
wide commitment to the continuous improvement of
improvements through the development of new
our products and customer services. We are committed
materials and processing methods. We carry out a full
to the attainment of ISO TS 16949 registration. As a
range of testing, analysis and monitoring activities at
result of quality ratings by our customers, as well as
both the plant level and at the ABC Group’s customer
the internal quality system audits we conduct regularly,
accredited
research
l a b o r a t o r y.
the ABC Group has received numerous quality awards.
Microtome analysis is a key Quality Assurance
procedure for products such as fuel transfer
products and other fuel systems and components,
which use multi-layer materials. Microtoming enables
measurement of the complete structure of each
layer of material.
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ABC Group’s environmental chamber has the capability
to facilitate a variety of temperature and humidity
tests for items ranging from small components to
full-sized vehicles. Load deflection and instrumented
impact tests are also completed within the walk-in
chamber.
Process Control methods include the use of Coordinate Measuring Machines to verify process accuracy by comparing customer
specifications with point-to-point measurements on product samples. CMM analysis also provides quality assurance support in
our mold-making operations.
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Research and Development
In plastics processing, the challenge of research and
faster and more effective scale-up, one of the most
development is to work simultaneously in several
important development advantages we can offer our
different areas — to create new synergies in the way
customers, we also design and fabricate specialized,
materials, tooling and processing technologies perform
project-specific test fixtures. At our customer-accredited
together on the production line. Our scientific and
laboratory, pilot-scale systems duplicate every process
technical expertise in each of these fields, and our
used at ABC Group manufacturing facilities. These
ability to balance and integrate them in innovative
machines are used for trial molding and experimental,
ways, represent a cornerstone of the ABC Group’s
prototype and production trials.
ability to continuously add new value to our customer’s
products.
processing technologies and materials engineering.
The ABC Group Tech Center’s research and
Apart from our innovations in blow molding, we have
development facility provides ongoing support for our
achieved major advances in injection, co-extrusion and
worldwide operations, and leads the advanced
other specialized processing techniques. These efforts
research programs that promise to redefine and
have produced dramatic results, and will continue to
strengthen our production capabilities into the 21st
serve as a catalyst for developing exciting new
century.
manufacturing systems and products in response to
evolving and fast-changing customer needs.
Our research programs focus on product
Long-term research strategies focus on new
development support, specifically aiming to achieve
Active Knee Bolster
ABC Group developed an Active Knee Bolster that deploys
to reduce lower limb injuries. The blow molded construction
eliminates the need for an air bag and housing. In addition
to providing enhanced occupant protection the Active Knee
Bolster allows the vehicle to have a more spacious interior.
This product is manufactured from a specially developed
material by Salflex Polymers Ltd. (an ABC Group company).
The ABC Group holds more than a hundred patents on processing
and material technologies. Our research goal is to ensure the
continuous improvement of existing processes and materials, and
to explore and develop new possibilities for our core blow molding
expertise and other processing capabilities.
Blow Molded Running Boards
A structural blow molded running board is made with
material designed by Salflex Polymers Ltd. (an ABC
Group company). The idea of the product is to have
molded structure that meets appearance requirements
in one single piece. The structure must meet rigorous
durability requirements at temperatures between -40˚C
and 88˚C . The product can also be designed to meet
upper class vehicle styling which can include lights,
accent edges and high gloss paint.
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We conduct ongoing quality assurance testing and analysis
using samples from every processing system used in our
plants worldwide. We are directly involved in long-term
materials development, blending and alloying. New initiatives
include materials research for improved capabilities in in-mold
decorating, finishing and painting techniques.
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People: Our Driving Force
Product innovation through technological leadership is the key to the ABC Group’s success. And the key to
our technical strength has always been our people. To continue to expand our business globally, and to
remain competitive and responsive to the needs of our customers, the ABC Group’s number one priority is
to attract, develop and retain the best people for every job in every facet of our organization.
Viewed as an investment in people and a further improvement in product quality and overall
productivity, our human resource development programs cover the full spectrum of our business
operations, and they involve employees in every occupation, at every level of experience. At the ABC
Group Tech Center, we provide industry and client-based courses covering people skills, including
management training, as well as technical qualifications, such as advanced product quality training. We
also conduct internally produced training and employee development programs, and we encourage all
employees to pursue career advancement and development opportunities. Largely through programs such
as these, much of the ABC Group’s middle and senior management strength has been developed
internally.
“We believe our most important resource is our people. We practice an open
door policy to encourage communication throughout the companies. We strive
to create a safe workplace, where fairness, equity and non-discriminatory
practices are the foundation of an environment for all parties to function as a
team and in doing so improve the quality of life.”
— from the ABC Group’s Human Resource Policy
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New Directions
Our corporate strategy is predicated on a vision of the 21st century in which the ABC
Group of Companies will produce entirely new classes and lines of automotive
products, operating within imaginative, synergistic business alliances in new markets
on every continent.
We will continue to focus on designing and producing innovative product systems
and modules. As a customer centered, strategy-driven supplier, we are positioning
our organization to mobilize the technologies, expertise and business relationships
that will strengthen our ability to deliver significant value to our customers
throughout the world. Above all, we remain committed to nurturing and further
expanding the human and technological resources that make product innovation
and service excellence achievable. We believe that our values and goals, which have
helped us become an international company in less than two decades, will continue
to guide us to our next plateau.
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