ANG Hutc - Hutchinson

ANNUAL REPORT
2004
www.hutchinsonrubber.com
CONTENTS
▼
The Group
Business Activities
2
11
Management Committee
Business Activities
3
12
Chairman’s message
Automotive Fluid Transfer
Systems
4
Key figures
2004
6
Research & Development
8
Quality, Safety
and Environment
10
Personnel
14
Body Sealing
Systems
16
Transmission
Systems
18
Automotive
Antivibration
20
Precision Sealing
Systems
22
Aerospace - Industry
26
Consumer Products
PROFILE
▼
THE GROUP
THE HUTCHINSON GROUP
Hutchinson, world market leader in the industrial rubber sector,
is a partner of various leading industrial groups in
the automobile, aerospace, railways, general industry
and mass distribution market segments.
Hutchinson’s business is organized into seven Activities:
Automotive Fluid Transfer Systems, Body Sealing Systems,
Transmission Systems, Automotive Antivibration, Precision
Sealing Systems, Aerospace & Industry and Consumer
Products. These Activities are gathered into two main
Divisions: Automobile-Industry and Consumer Products.
Hutchinson, a company of the Total Group
Hutchinson is part of the Total Group Chemical Branch
and operates principally in Europe, North and South America
and in Asia.
At the end of 2004, Hutchinson employed 25,275 people
in 148 production and sales sites in 31 countries.
1
MANAGEMENT
COMMITTEE
▼
General Management
Pierre-Christian Clout
Chairman and Chief Executive officer
Management Committee
Gilles Argy
Corporate Vice President,
Research and Development
Dominique Bonnet
Corporate Vice President, Finance
René-Jacques Quignard
Corporate Vice President,
Human resources
and Communication
Board of directors
Pierre-Christian Clout
Chairman, 2006
Robert Castaigne
2005
Jacques Maigné
Corporate Vice President,
Aerospace- Industry
Françoise Leroy
2004
Éric Perrot
Executive Vice President
Total Chimie S.A.
2004, Represented by Ian Howat
Functional Management
Auditors
Jean-Pierre Joubert
Corporate Purchasing Director
Barbier-Frinault et Autres
2008
Dominique Mounier
Legal Counsel
Alternate Auditors
Christian Chochon
2008
2
▲
From left to right,
First line:
Jacques Maigné,
Pierre-Christian Clout,
Dominique Bonnet.
Second line:
René-Jacques Quignard,
Éric Perrot, Gilles Argy.
The terms of office
for Board members
and Auditors expire
on the day the Annual
Shareholder’s Meeting
is convened to approve
the accounts for
the fiscal year indicated
after their names.
HUTCHINSON IN 2004
THE GROUP
CHAIRMAN’S
MESSAGE
▼
In an evolving and contrasting environment,
Hutchinson’s growth was carried forward. At constant
exchange rates (6.2 percent) the turnover covered
an average growth rate in Europe to a high growth
rate in the NAFTA and South American regions.
Profitability was maintained despite a constant pressure
on prices from customers and on the increased cost
of raw materials, particularly steel.
The Automotive market recorded mixed developments
with a 4 percent increase in production for Europe, flat
for the NAFTA countries and a highly significant growth
for South America and Asia. Industry markets behaved
well, but consumer products did not record any major
business revival.
The Group’s headcount progressed in the NAFTA region,
Mercosur and Eastern European countries. In France,
the number of employees remained stable.
Our profitable growth policy is carried out from
a Sustainable Development angle, taking on board
the environmental protection issues and the safety of
our people. Efforts towards a prevention of risks
at the workplace were translated into a major reduction
of accidents with days off, thus offering more secure
work conditions to our personnel.
As world leader of elastomer processing, and thanks to
the skill and dynamism of its women and men, Hutchinson
has successfully adapted to the diverse geopolitical
upheavals the industrial markets are faced with.
Industrial investment applied to an increased production
capacity in strong demand countries, such as Poland,
Mexico, Portugal and China.
Research and development spending was carried forward
at a level enabling the development of a great number
of new, high technological innovation content concepts,
and the renewal of our ranges of products.
Pierre-Christian Clout
Chairman and Chief Executive Officer
3
2004 KEY FIGURES
ECONOMIC YEAR
TURNOVER
▼
▼
During the year 2004, the Hutchinson Group’s
turnover was up 3.5 percent over 2003.
At constant exchange rates, this evolution
translated in a growth of 6.2 percent.
By market
segment
The Group’s market places recorded a contrasted
evolution:
• growth in the Automotive production sector in
Europe (+4.1%) and in South America (+26.5%)
and stability in the NAFTA region,
• global growth in the industrial sector where
Hutchinson operates, and namely in the USA,
• still sluggish consumer products markets.
By geographical
area
63%
31%
Automotive
France
Under these conditions and despite the pressure
from customers for higher price concessions,
the Group’s relative profitability was maintained.
23%
United States
Capital expenditure and Research and
Development investment were also maintained.
15%
Germany
20%
Industry
25%
Other European countries
17%
Consumer
products
6%
Rest of world
4
THE GROUP
SUSTAINED GROWTH, INCREASED INVESTMENTS
AND R&D SPENDINGS
▼
(in € millions)
2000
2001
2002
2003
2004
2,551
2,675
2,709
2,575
2,667
2000
2001
2002
2003
2004
153
136
115
114
118
2000
2001
2002
2003
2004
With a 3.9 percent increase over 2003, R&D
spending amounts to 5 percent of turnover.
110
124
124
129
134
Employees
2000
2001
2002
2003
2004
At December 31, 2004, the Group Hutchinson
employed 25,275 people in operations covering
31 countries.
23,872
24,169
24,820
24,564
25,275
Industrial sites
2000
2001
2002
2003
2004
With 95 plants located in 18 countries,
the Group is ready to respond to the
requirements of its main customers.
96
96
94
95
95
Growth
Turnover is up (+3.5%) over 2003. At constant
exchange rates, and by geographical region,
the increase of +6,2% is viewed as follows:
Europe
+ 3,6%
NAFTA Region
+ 13%
Other countries*
+ 10,3%
* South America/China.
Capital expenditure
(in € millions)
Investment in both tangible and intangible assets
totalled 118 million euros, a slight increase over
2003. This amount corresponds to 4.4 percent
of turnover.
Research and Development
(in € millions)
5
RESEARCH AND DEVELOPMENT,
THE DRIVING FORCE
TOWARDS GROWTH
In 2004, Research & Development spending reached
134 million euros, up 4 percent over 2003.
These expenditures amounted to 5 percent of the
consolidated turnover, which shows the importance
placed by Hutchinson on R&D activities, the firm’s
driving force.
The Hutchinson R&D activities can be said to globally
focus around four poles:
•
•
•
•
Materials:
Materials purchases amount to nearly 30 percent of
the group’s total sales. They represent a priority on four
main focus lines:
optimised formulation of the compounds, aiming at cutting
down our production cost
improved technical performances (heat resistance, fatigue
stress behaviour, resistance to chemicals…)
Invention of new families of high performance
Thermoplastic Elastomers (TPE) Vegaprène®‚
enhanced “robustness” and more regular technical
characteristics in the elastomer compounds produced in
order to comply with “6 sigma” quality oriented challenge.
The focus is no longer on polymers only and the
Corporate Research Center (CRC) now has available
a design laboratory with high performance means
for metallurgic and metal works studies.
Digital simulation
The CRC Computing Center has a supercomputer whose
computing power was significantly increased during 2004,
to reach a level of 500 billion operations per second
(0.5 TeraFlops), one of the most powerful in France.
This host computer is connected to about fifteen different
sites worldwide (France, Spain, Germany, United States…)
and the users on our various sites have full transparent
access to it.
In the software side, function-dedicated software (for specific
applications) has become common place in order to cut down
computing time and provide better access to an increased
number of users.
6
Product developments
Various product developments are currently in place
or in early marketing phase.
In the Automotive sector, active electronic antivibration
devices, the LINKEO‚ exhaust line hose with outstanding
vibration attenuation performances, high performance
elastomer air hoses for engines, the new TPE
Vegaprène®‚ air conditioning flexible hoses, structural
heat expanding sealants, and various TPE Vegaprène®‚
moulded parts, should emerge an in-depth renewal
of our product portfolio in the years to come.
In the Industry sector, Paulstra has comforted its position
as aerospace and railway segments leader, with brand
new results such as the review of the engine suspension
system of the future A400M European military air carrier,
or with orders for the Canton underground vibration
attenuation systems.
The development of new, enhanced performance and
more light-weight safety devices for run flat (civil security
and military applications) consolidate Hutchinson’s
position as worldwide leader on this market.
On the consumer products sector, 2004 was the beginning
of the G-VIR medical gloves marketing, and
the development of new, more comfortable and softer
household gloves – the Flex Comfort Technology.
Process
Capability improvement, waste and rejects level cut down,
and enhanced productivity represent the major processoriented lines of development, with one priority: reduction
of rejects and compliance with environmental constraints.
In the field of extrusion, a major effort was carried out
on developing volumetric pumps to obtain more regular
extrudate, and the project of developing extrusion dies
by stereo lithography has reached the pre-industrial stage.
On non-destructive controls, efforts aiming at developing
sophisticated software for signal processing ensured
increased precision and robustness of various control
processes and, thus enhanced reliability and compliance
with products specifications.
THE GROUP
1 Massively parallel computer. 2 Anechoic accoustic chamber. 3 Fatigue stress machine.
1
2
3
7
QUALITY, SAFETY
AND ENVIRONMENT
1
Quality
Following implementation of various quality management
systems compliant with the latest standards in force,
and following a significant improvement of performances
and having successfully stabilized its non-quality costs
over the last years, Hutchinson is currently committed
towards operational excellence.
At the end of 2004 and with very few exceptions,
all the Group sites had a quality management system
(Q.M.S.) complying with the latest international standards
in force: ISO 9001-2000, ISO/TS 16949-2002
for the Automotive Industry sites, EN 9100-9003
for the Aeronautics Industry sites.
Compliance of our Q.M.S. to these standards has widely
been acknowledged following various third party audits
carried out in our plants along 2004.
The Group has currently available 140 official “quality”
certificates in 90 of the sites.
Thanks to Q.M.S. based on the latest versions of
the standards in place, thanks also to the fact the process
management is of constant practice in the field now,
Hutchinson and sites are deeply rooted to go ahead
towards excellence in quality.
The increasing efficiency of the Group QMS should be
underlined, especially in view of the constant reduction
of the number of non complying parts supplied to our
customers over the last years.
In the Automotive industry, the number of non-complying
parts are measured with the PPM (number of defective
parts per million parts supplied) indicator. Such parts
represented a significant low level in 2004 for
the Transmission Systems (PPM < 20), the Automotive
Antivibration (PPM < 25) and Fluid Transfer Systems
High Pressure (PPM < 100) Activities.
The route towards excellence was opened as early as
2001 through the RECORD project (associated to it were
22 million euros savings from rejects and in industrial
performance gain at the end of 2004), and was recently
given a further boost within a global project to be
progressively deployed throughout the Group until the end
of 2007.
8
The successor to RECORD, a project based on cost
reduction from rejects and defects in production, is a new
operational excellence project oriented to three topics:
• Management of the site, from a transverse and
subsidiarity angle.
• Monitoring and optimization of processes, more widely
of all operational processes.
• Control of all types of purchases, from the suppliers’
quality assurance angle.
To meet this objective, various tools and methods such as:
the B.S.C. (Balanced Score Card), an exhaustive
production system, self-appraisal of a progress approach,
standard indicators of performance measurement etc.
are progressively implemented in all the Group sites,
based on their size and activities.
Safety of people and goods
A stronger involvement and the establishment of
the SAFERING programme, focused on risk prevention at
the work place, translated into a significant reduction of
the accident level in 2004 which retreated 30 percent
on accidents with days off (Frequency occurrence:
12.5 in 2003 vs. 9 in 2004).
A special emphasis was placed on more secure work
stations when using hazardous substances and on the
establishment of a noise abatement protection system.
A programme for the reduction of vulnerability to fire was
simultaneously pursued in collaboration with the
insurance company AON; it focuses on systematic fire
detection and on streamlining the raw materials, current
production and processed products storage conditions.
Given that no damage has ever occurred over the last five
years, assessing this programme’s efficiency is obvious.
2
THE GROUP
1 Zywiek 1 workshop, Poland. 2 Winners of the 2004 Presdient Award for Sustainable Development. 3 The Columbia (TN) processing unit, United States.
3
Environment
The Montargis site received an ISO 14001 certification
in 2004, 48 sites of Hutchinson are now certified;
Hutchinson currently has all major sites and its
automotive industry plants certified, which represents
a validation of the environmental policy initiated over
10 years ago with a sense of responsibility.
Major environmental factors:
Water
• The reduction of water consumption was continued, as
a follow-up to previous investment on looping the cooling
circuits; an almost fifteen percent reduction was obtained
on water mains (1.72 Mm3 in 2003, 1.57 Mm3 in 2004).
• The internal treatment stations operation was streamlined,
with a reduction of the COD (Chemical Oxygen Demand)
assessed at 20 percent (850 tons in 2003, 700 tons
in 2004).
A 75% REDUCTION OF THE SULPHUR-BASED
EMISSIONS INTO THE AIR
▼
•
•
•
•
Air
The CO 2 emission level was reduced (4,000 tons less
over a total 180,000 tons), going from fuel oil to gas
in the Brazil sites in particular.
The emission VOCs (Volatile Organic Compound) were
reduced; investing in a carbon sulphide processing unit
in Columbia/USA brought a 600 tons reduction of
emissions at constant production regime, or over
10 percent of the Hutchinson’s emission level assessed
at 5,000 tons (refer to note below).
Methanol will be no more used in the gloves production
process (operational in two plants, to be implemented
in Malaysia), representing 200 tons less emission at
constant production regime immediately and 400 tons
less over the next 3 years. This innovation was awarded
with the Hutchinson’s President’s prize in 2004,
Sustainable Development Award.
Major investments in the collection area (air related
investment in 2004 for over 4 million euros) are paving
the way to 2005 and 2006 future investment on
processing and will significantly cut down the
Hutchinson’s COVs emissions.
The American agency for environmental protection
announced in June 2002 that 75 percent of
the sulphur rejects emission linked to the production
of cellulose sponges on the American territory had
to be cut down.
To comply with this official demand, Mapa Spontex
opted for a novel process, the catalytic oxidation for
processing sulphur compounds. This catalyst-based
technology provides a self-maintained reaction with no
energy brought from an external source as long as the
gas concentration is adequate. Sulphuric acid can, in
addition, be generated from the oxidation product
(sulphur anhydride) in contact with water. This acid is
part of the sponges’ production process; the amount
produced meets production needs.
Operating costs for this 3 million dollar installation are
rather low. Commissioning is due for June 2005.
9
PERSONNEL
1 Fit Profiles celebrating its 80th anniversary. 2-8 Some diversity
among our employees: Nicolas Niollet, Automotive Fluid Transfer
Systems (2); Emmanuelle Moisy, Body Sealing Systems (3);
Antonio Sanz, Transmission Systems (4); Robert Kuo, Automotive
Antivibration (5); Thomson Rovalier, Aerospace-Industry (6);
Virginia Ramos, Precision Sealing Systems (7); Anne-Lise Villaumié,
Consumer Products (8).
In a highly challenged environment, both in countries
and on the market segments, Hutchinson remained
open to growth thanks to the motivation and
adaptability of it’s employees.
While turnover was up 6.2 percent, the Hutchinson
personnel increased by some 3 percent.
The headcount went up by over 8 percent on
the American continent. There were increases both in
the Nafta region and, more so, in Mercosur. In Europe,
the 4.2 percent increase in personnel came from a strong
development of Eastern European countries, while
Western Europe recorded stable staffing levels.
1
2
4
3
This need to feel deeply-rooted might put a brake on our
necessary adaptation to changes on our market segments.
However, mindsets are boosted as exchanges are
organized among our firms. For example, such are the days
at St-Etienne when the Allègre site hosted a team from
Mapa Zeven to get to know them better and to exchange
ideas and to work on the Baby-care product line.
It is by successfully combining these various cultures that
Hutchinson will adapt to changes.
5
6
8
7
10
To this stability in the headcount is added a weak renewal
rate. At a time of evolution in sophisticated technologies
sectors, this might seem a surprising fact, but this loyalty,
this tie with our Group is there to note. An example of
the importance of feeling deeply-rooted was shown in
Moirans for the 80th-year celebration of Fit Profilés.
The same applied to the Caceres “Open Day” in Spain
to celebrate the firm’s 30th anniversary.
14
Automotive Fluid
Transfer Systems
Senior Vice President
Christian Leys
Body Sealing Systems
Senior Vice President
Patrick Rouyrre
16
18
Transmission Systems
Senior Vice President
Michel Thiallier
Automotive Antivibration
Senior Vice President
Thierry du Granrut
20
22
Precision Sealing
Systems
Senior Vice President
Jacques Helfer
Aerospace-Industry
Senior Vice President
Jacques Maigné
BUSINESS ACTIVITIES
12
26
Consumer Products
Executive Vice President
and Director of Division
Éric Perrot
11
AUTOMOTIVE
FLUID TRANSFER SYSTEMS
BRANDS/COMPANIES
MARKETS
▼
▼
Hutchinson Argentina
Hutchinson Autopartes
Mexico
Hutchinson Borrachas
de Portalegre
Hutchinson Brasil
Automotive Ltda
Hutchinson DEFDC
Hutchinson Flexibles
Automobile
Hutchinson FTS
Hutchinson GmbH
Hutchinson Industrias
del Caucho
Hutchinson Palamos
Hutchinson Poland
Hutchinson Porto
Hutchinson SNC
Hutchinson Srl
Hutchinson Sro
Hutchinson UK
Automotive:
Air-conditioning
Air intake
Brakes
Engine cooling
Engine and engine suspension
Filtration
Fuel line
Lubrication
Oil cooling
Power steering
Steering
Transmission
Tokai (alliance)
SITES
▼
❏ ■
Argentina
Brazil
China
Czech Republic
France
Germany
Italy
Mexico
Poland
Portugal
Spain
UK
USA
❏ ■
Japan (alliance)
❏ ■
❏ ■
❏ ■
■
❏ ■
❏ ■
❏ ■
❏ ■
❏ ■
■
❏ ■
▼
3D blow-molded water
or air ducts
Air-conditioning hose assemblies
Brake system hose assemblies
Canisters
Clutch hose assemblies
Air-conditioning hoses
Depollution hoses
High-temperature air hoses
Oil cooling hose assemblies
Oil hoses
Plastic and rubber fuel hoses
Power steering hose assemblies
Water hoses
For the Low Pressure segment, year 2004 was
characterized by:
• A strengthening of the production units in “low cost”
countries to better meet customers’ needs.
• A diversification of products to satisfy technical
expectations of the car and equipment makers
(common-rail, particle filters, fuel injection).
Sales were globally equivalent to year 2003 results.
The Polish sites experienced a strong upswing in
production, in particular in the field of fuel fluid transfers.
On the American market segment, production was
initiated in good conditions in the Celaya (Mexico) plant.
Significant means were invested on quality to secure
more reliable structures and to better satisfy the needs
in the automotive market segment.
Developments were extended in interconnection systems,
structures, high pressure hoses, and through a more
scientific approach of any technological problem.
The activity experienced major progress in all its market
segments thanks to the stability of its teams in the startup
units and to a better knowledge of the individual work.
▼
❏
PRODUCTS
For the Automotive Fluid Transfer Systems Activity,
2004 was a year of consolidation in “low cost”
countries for the Low Pressure business and of
development in these same countries for the High
Pressure business.
12
❏
■
Sales
Production
Air conditioning hose and pressure
connection duct for particle filters.
WITH HUTCHINSON,
NO MORE BLACK
POLLUTING PARTICLES
FROM THE EXHAUST
PIPE!
▼
The amount of carbon
particles emitted in the
air through the exhaust
gas is cut down thanks
to the particle filters
installed on the exhaust
pipes of diesel-fuelled
vehicles. Because of
this filter clogging up,
we have developed
a differential pressure
sensor piping system,
which measures the
loss in load through
the filter.
BUSINESS ACTIVITIES
1 A 5-layers extrusion line with control system. 2 Pressure connection hoses on particle filters.
1
On the High Pressure business segment, year 2004
recorded a higher sales level over 2003, despite a harsh
competitive environment.
With automotive and equipment manufacturers pressing
for price concessions and higher productivity, the decision
was taken in Europe to invest: in a unit solely dedicated
to hose assembly located near Bielsko Biala (Poland);
in the extension of the Porto (Portugal) unit; and,
in the start-up of a production workshop in Celaya
(Mexico) for the American continent.
Sites located in the north of the United States were
streamlined thanks to a new site in Quincy (Michigan).
In both the European and the American market segments,
business was won, and year 2005 looks quite promising
in terms of sales growth.
Major spending in mechanical and automated controls
was carried out from an industrial point of view.
On the R&D front, emphasis was placed on rationalizing
flows/circuits, on adapting structures to German
specifications and on the development of new air
conditioning assembly systems.
Streamlining was performed among the research and
development teams in Europe in particular, to offer more
consistent solutions to customers.
2
OUR SOUTH AMERICA
ACTIVITIES
▼
The Hutchinson Brazil Automotive Activity recorded
significant growth in 2004 with a major progression
of business supported by domestic market growth and
by exports to Spain and Mexico. It translated into
increased production capacity in various segments:
• A 1,000 m2 building was constructed in Extrema
for the Automotive Fluid Transfer Systems in order
to streamline the extrusion of the brake hoses, thus
cutting down production costs and retaining the Ford
market segment. New production parts were launched
for the new VW Fox vehicle to be marketed in Europe
as successor to the Lupo.
• Two buildings were purchased in Monte Alto for the
extension of the Automotive Antivibration Activity on
6,600 m2 and of a logistics area and finishing shops of
the Body Sealing Systems Activity over 18,000 m2.
• In the Transmission Systems Activity, two buildings
were constructed in the Monte Alto plant 2:
3,500 m2 for 6 future extrusion lines and 1,200 m2 for
the rubber sheet calendering shop.
Operations in Hutchinson Argentina also recorded
a strong improvement in 2004, where new parts were
developed for the Peugeot 307 and the Ford Focus.
For the future Toyota-Hilux Pick-Up Truck, parts
produced by the Automotive Fluid Transfer Systems
and Automotive Antivibration Activities were jointly
designed with Bridgestone.
13
BODY
SEALING SYSTEMS
BRANDS/COMPANIES
MARKETS
▼
▼
Hutchinson Argentina
Hutchinson Autopartes
Mexico
Hutchinson Brasil
Automotive Ltda
Hutchinson DFEDC
Hutchinson GmbH
Hutchinson Industrias
del Caucho
Hutchinson Poland
Hutchinson Sealing
Systems Inc.
Hutchinson SNC
Hutchinson UK
Automotive:
body and interior
SITES
▼
❏ ■
❏ ■
❏ ■
❏ ■
❏ ■
❏ ■
■
■
❏ ■
▼
Dynamic seals:
Door seals
Double seals
Dust seals
Hood seals
Radiator tank seals
Trunk/rear door seals
Fixed window seals:
Bonded window trim
Glass encapsulation
Rear quarter panel seals
Opening window seals:
Glass run channels
Internal and external waist
seals
Internal door GRC
Business won confirmed hopes for growth in the near
future, due mostly to innovating, good added value
products, such as run channels of the “hidden frame”
family. This type of run channels is now mounted on some
35 percent of the new vehicles and offers both
functionalities of double sealing and glass run channels,
while presenting a higher quality aspect and acoustic
comfort meeting the market segment’s expectations.
Deployment of production in South America, Mexico,
Poland and recently China continues. At the same time,
Spain is developing in line with local needs.
Productivity and quality efforts are everywhere and should
enable all sites to reach the same level of excellence.
All sites are certified TS 16949 and ISO 14001.
The product/process development is a major focus line
for improving services to customers and delivery
achievement; progress as initiated by the CATIA V5
technology is promising for the future, thanks to a drastic
reduction of the time-consuming and repetitive
digitalization stages. Our knowledge of a physical
phenomenon such as the closing of a door was amplified
for the first time ever, thanks to digital modelling, a world
wide premiere. Products are more cosmetic now: TPE
encapsulated glazing modules or glass run channels
and waist seals with chrome aspect.
2004 was the year for launching various equipment for
new vehicles (from most of our customers), offering
a lasting growth on global volume and related marketing
development. Such is the case of the South America
Toyota Hilux.
▼
❏ ■
Argentina
Brazil
China
France
Germany
Mexico
Poland
Spain
UK
USA
PRODUCTS
Production volumes of the Body Sealing Systems
Activity considerably increased since 2003 on its three
main market segments: North America, South America
and Europe, despite a relatively dull global market.
14
❏
■
Sales
Production
Hidden frame glass run channels.
WITH HUTCHINSON,
SUSTAINABLE
DEVELOPMENT
IS PROVIDED!
▼
We were the first for
this type of parts to
combine three materials
(TP, TPV and TPO)
associated to a thin
aluminium strip for the
production of fully
thermoplastic hidden
frame seals. The frame
is thus made of lighter
(40 % weight reduction
of the frames), recyclable
materials
1 New thermoplastic technology workshop – Hutchinson Sealing Systems.
BUSINESS ACTIVITIES
2 Roland Stecher, in charge of production, Aachen, Germany.
1
2
The market is rapidly evolving, customers are building new
production sites in emerging countries and Hutchinson
must follow to produce where new markets are.
For some sites such as the Aachen plant, this production
relocation means major changes, and turnover is often
increased with the same headcount, number-wise. Aachen
represents a highly automated production system
on either finished or semi-finished products sent
essentially to Poland where well qualified manpower
is in charge of the production finishing in proper
economic conditions, on equipment defined and tested
in Aachen. This explains why, in Germany, the extrusion
capacity has developed close to the mixing room. Special
attention is given to safety. Processes are made safer and
procedures are explained during a training period;
the system works well given that Lodz (Poland) has
recorded no-accidents over the last 2 years.
15
TRANSMISSION SYSTEMS
BRANDS/COMPANIES
MARKETS
▼
▼
Deutsche Hutchinson GmbH
Hutchinson Argentina
Hutchinson Brasil
Automotive Ltda
Hutchinson DFEDC
Hutchinson Industrias
del Caucho
Hutchinson FTS
Hutchinson SNC
Hutchinson SRL
Hutchinson Poland
Hutchinson UK
Automotive
Aerospace
Agriculture, fishing
Food industry
General industry
Home appliances
Marine
Railways
Sports and leisure
Transportation
Hio Il (sales representative)
Bando (partnership)
PRODUCTS
SITES
▼
❏
❏ ■
❏ ■
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South Korea (sales
representative)
Japan (partnership)
Poly-V® belts
Polycran® belts
Pulleys
Tensioners
Idlers
Thanks to dynamic teams in all its segments and to proven
transverse operational methods, the Hutchinson
Transmission Systems Activity is a world market leader
in its field.
Hutchinson Transmission is in a position to secure
for its customers the best technical and economic
solutions in the automotive, home appliance and general
industry sectors, thanks to:
• full expertise in predictive calculation and simulation,
which is constantly improved by the Corporate Research
Centre, and the best international experts; and,
• the quality and reliability of its products and services.
In the automotive industry, EPDM belts, especially the
stretchy one provide added simplicity of use, hence
reduced weight and cost for the drive system as a whole.
Following FORD and GM, be it in the United States,
Europe or Asia, these products equip Mercedes, VAG,
Suzuki, Hyundai and KIA with innovations “Made in
Hutchinson”.
In the home appliance sector, Hutchinson is a world
market leader on the drive belts for the washing machine
and tumble dryer market segments. Its technical
know-how is acknowledged on all continents and major
world manufacturers currently use the Poly-V® stretchy
belt with adapted modulus.
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Argentina
Brazil
China
France
Germany
Italy
Poland
Spain
UK
USA
▼
The year 2004 was a year of rebound for
the Transmission Systems Activity in the automotive
industry and a year of continuing strong growth
in the home appliances and general industry sectors.
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Sales
Production
EPDM belts and decoupling pulleys for the
automobile vehicles.
WITH HUTCHINSON,
DAILY LIFE
IS SIMPLIFIED!
▼
By means of elastic belts,
automatic tensioners,
pulleys or idlers, our
transmission systems
offer leading-edge
technology for all
industries. When using
your washing machine
or tumble drier we
provide for you both
simplicity of installation
and savings on weight
and cost.
BUSINESS ACTIVITIES
1 Engine front end accessory drive. 2 Workshop in Extrema, Brazil. 3 Workshop in Lodz, Poland.
1
As to its specific and numerous applications in
the industry marketplace, the Flexonic® stretchy belt
demonstrates its unique features, performance
and competitive advantage on a larger number of
innovating machines in sectors as different as fitness
machines, compressors, vacuum cleaners, material
handling machines and agricultural equipment.
Hutchinson Transmission production sites are located
in Western Europe, Poland, Brazil and soon China, using
a fully mastered process. All plants are certified ISO
9001 and ISO TS 16949/2002.
Furthermore, within the framework of ISO 14001
certification, Hutchinson sustainably contributes to
the protection of the environment, seeing to the safety
at work and well-being of its staff, and in keeping with
the urban and industrial environments where it is present.
2
3
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AUTOMOTIVE ANTIVIBRATION
BRANDS/COMPANIES
MARKETS
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Deutsche Hutchinson GmbH
Hutchinson Argentina
Hutchinson Brasil
Automotive Ltda
Hutchinson DEFDC
Hutchinson Poland
Paulstra CRC
Paulstra Iberica
Paulstra Italia
Paulstra Ltd.
Paulstra SNC
Automotive:
body and interior
engine and exhaust
steering
suspension
Bridgestone AVS (alliance)
Kurashiki Kako (licence)
Teklas (licence)
SITES
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Japan (alliance)
Thailand (licence)
Turkey (licence)
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Active and semi-active
engine mounts
Body and cradle mounts
Engine mounts
Exhaust hangers
Hydraulic engine mounts
Hydraulic bushes
Linkage
Mass dampers
Steering couplings
Strut mounts
Suspension bushes
In Europe, in a slight growth environment in
the Automobile manufacturing sector, the Automotive
Antivibration Activity has grown significantly thanks to
the production launching of new projects, such as:
the Renault Modus, the new Ford Focus, the Mercedes
A Class, the BMW 6 series and the Peugeot 407.
The 607 benefits from the Active torque rods equipping
the latest 6 cylinder diesel-engine. This new product was
developed in joint collaboration with PSA, and is produced
at our site in Chateaudun.
In North America, Paulstra CRC successfully progressed
on production start-up in several programs for its major
customers’ new main model ranges: the latest Ford
Mustang model; the Chevrolet Cobalt and Equinox;
the Buick Rendez Vous and Lacrosse; the Chrysler 300
and Dodge Magnum; and, the Daimler Chryslers’ Cadillac
STS. Thanks to these newly launched programs, the
production volumes progressed in a relatively flat market.
In 2005, more favourable economic conditions and new
programs start-up such as the new Pontiac sedan
and the Saturn Vue, as well as continuous productivity
and purchasing efforts should open up on higher results.
In the South American market, Paulstra’s turnover was
significantly up in this sustained growth market
environment. This increase led to extend surface,
production and development means in Argentina,
especially to prepare the production of a high number of
parts for the new Toyota Hilux. Moreover, Paulstra also
acquired a new production site in Brazil, which will enable
a multiplication by four of our local production capacity
within the near future, and increased export volumes.
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Argentina
Brazil
China
France
Germany
Italy
Poland
Spain
UK
USA
PRODUCTS
The Automotive Antivibration Activity experienced
a contrasted rate of activity in 2004 based on
the geographical area concerned.
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Sales
Production
Active torque rods for the Peugeot 607.
WITH HUTCHINSON,
GAIN IN COMFORT
WITHOUT VIBRATION!
▼
When the driver of a
diesel fuelled, automatic
gearbox vehicle puts the
stick on the D position,
an unpleasant buzzing
is felt together with
increased vibrations.
The active torque rods
developed by Paulstra
provide both a good
acceleration torque and
comfort in idle position.
1 Hydrovacuum automated system in Chateaudun, France. 2 Roboquad in Grand Rapids, U.S.A.
1
In early 2004, the cost of raw materials, in particular steel,
significantly increased in North America followed by all
other continents. This unexpected situation combined with
lower sales prices in a highly competitive environment had
a negative impact on our results.
However, major investment, in automated equipment
essentially, and lower purchasing costs succeeded in
limiting such impact. We are not expecting any major
reduction in the cost of raw materials for 2005 and
purchasing performance is more than ever indispensable
to satisfy the automotive manufacturers’ demand. In 2004,
Paulstra strengthened its means and organization to
resource the purchase of material and components
required for its products where the suppliers’ offer are
most competitive.
Multi-annual “Spring” progress plans were implemented,
in parallel, to bring our industrial sites to the level
of excellence of their respective business. In addition,
an indispensable capacity and productivity capital
investment program was carried out.
3
2
BUSINESS ACTIVITIES
3 Measurement laboratory in the Corporate Research Center/Montargis, France.
In terms of development, Paulstra was the designated
supplier for numerous vehicles in Europe during 2004,
in particular by PSA, Renault-Nissan, and Toyota for
the renewal of its Corolla range based on our alliance
with Bridgestone. Developments extended also in China
and Korea where Paulstra is doing more business with
local makers.
In North and South America, Paulstra won several
industrial programs and its market share is going
to expand, in particular with General Motors.
LINKEO is one of the most innovative products presented
in 2004 to the market to meet new technical challenges
and to improve the vibration and acoustics comfort
in vehicles. LINKEO is a revolutionary exhaust line which
combines low stiffness and an unprecedented heat
insulation. It will also contribute to better environmental
performance of the engine and exhaust system, and was
well received by the market representatives. Integration
projects into vehicle developments are in progress.
19
PRECISION SEALING SYSTEMS
BRANDS/COMPANIES
MARKETS
▼
▼
Caoutchoucs Modernes
Catelsa
Desmarquoy
Deutsche Hutchinson
Hutchinson Brasil
Automotive Ltda
Hutchinson DFEDC
Automotive Seals Co. Ltd.
Hutchinson Poland
Hutchinson Seal
Intecsa
LJF
LJF Suzhou Co. Ltd.
Pamargan
Paulstra
Automotive:
air-conditioning
air intake
body and interior
brake systems
engine
engine cooling
filtration
fuel line
ignition
lubrication
steering
suspension
transmission
Construction & public works
Food industry, agriculture,
fishing
General industry
Sports & leisure
Transportation
SITES
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PRODUCTS
▼
Automotive molded parts
Automotive precision
rubber parts
Bellows
BS rings
Composite seals
Diaphragms
Dynamic seals
Encoders
Foam rubber sheet and blocks
Flat seals
O-rings
Quadrilobe seals
Radiator seals
The Oil Seals Division experienced major turnover growth
in Europe, supported by the leading product segments:
encoder seals, PTFE shaft seals, automatic gearbox
pistons and bearing seals.
In 2004, the line production of encoder seals for ABS
applications was launched for two Japanese bearing
equipment makers. Paulstra also won business as
the developer of magnetic encoders for various
mecatronic applications and continued a policy of product
and customer portfolio diversification.Thanks to its highly
offensive policy in the automatic transmission market
segment, Paulstra was selected in 2004 for various
developments, the recognition of their expertise and for
their proper use of synergies with other divisions of
the Activity.
The Division launched an investment plan to increase
the production capacity and initiate a training plan
in Brazil for business won in 2004. Production is
scheduled for startup in 2005.
The Precision Rubber Division saw vigorous sales
growth in Brazil.
Thanks to Division’s know-how in the “Blow-by”
diaphragms production (Gamaches), the launching of new
developments for leading equipment manufacturers on
this market segment was made possible. This diaphragm
regulates the oil vapor flow in the engine upper
compartment.
A zero-defect situation has been achieved thanks to
investment in these production line automatic controls.
Developing and starting a successful large series
production of overmolded flat seals for head covers
strengthened the Division’s position vis-à-vis carmakers
such as DCX, Renault and PSA.
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Austria
Belgium
Brazil
China
Denmark
France
Germany
Italy
Malta
Mexico
Norway
Poland
Portugal
Spain
Sweden
Switzerland
UK
USA
In the Precision Sealing Systems Activity,
the weakness of its market segments was largely
balanced by sustained sales growth, driven by
a portfolio of products with high technical innovation
content.
The year 2004 was characterized by further capital
spending in the Lodz (Poland), Ensenada (Mexico)
and Monte Alto (Brazil) sites.
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Sales
Production
Cylinder head gasket, overmolding of a 6.6 polyamide plate with
fiberglass reinforcement by self-adhesion rubber around, offering
resistance to engine oils and to temperatures up to 150 °C.
WITH HUTCHINSON,
OPTIMIZED AIR
CONDITIONING AND
ACOUSTIC COMFORT
PERFORMANCE.
▼
On the new A4Audi,
the “EP250” foam EPDM
parts of the Foam
and Converting Division
satisfy the emission
levels requirements and
provide perfect thermal
insulation. Comfort in
terms of soundproofing
can also be optimized
thanks to the various
anchor seals which
provide an interface
between the air
conditioning module
and the vehicle’s
passenger compartment.
With this highly flexible
Bulaflex range we provide
soundproofing and
tightness under
compression.
1 O-rings production line for gasoline line, Château-Gontier, France.
1
A perfect control of the plastic parts overmolding
operation with self-bonding rubber has won the Division
new business and, in particular, in the controlled air intake
devices market segment.
The O-Rings Division experienced continuing growth in
Europe resulting in the doubling of the market segments,
both in the O-Rings product line and in bonded seals or
similar products.
New qualification was obtained in the automotive
segment on gasoline (bio fuels, injection seals) and air
conditioning lines (German manufacturers), resulting in
a promise of growth for the years to come.
The new Ensenada plant was commissioned in Mexico
which now hosts all our production requirements for
the North American continent.
Industrial production and marketing activities in
the Mercosur market segment started from the Monte
Alto (Brazil) site.
The Foam and Converting Division globally consolidated
its positions on traditional market segments.
The year saw vigorous growth in the Bulatex cellular
blocks and the Briare site experienced a continued
refocus on the rubber foam parts core business.
The product range was renewed following replacement of
previous parts by new Bulatex parts.
The Intecsa plant experienced significant growth thanks
to thermoforming and the dynamics of the cutting system.
Montargis saw a significant increase of the technical
sheets and cellular sleeves production.
The Automotive Molded Parts Division recorded a major
sales progression, particularly on three of the product
families. We reached worldwide leading positions on
servo-brake diaphragms with production well over
15 million parts per year, thus ranking among the world
leaders. In addition, we won business as
supplier/developer for Toyota and Audi on the steering
bellows and on thermoplastic parts (Végaprène®).
BUSINESS ACTIVITIES
2 Main electrical beam, a two-materials part: Vegaprène®/Polypropylene 20% talc (powder).
The introduction of the Hutchinson material, Végaprène®,
in the field of automotive brake systems is ongoing.
As a complement to the mass production of the
servo-brake diaphragms for Bosch, we developed steering
bellows which are in first phase supply to 2 major players:
Bosch and TRW. Full mass production is planned on the
Peugot 207 for the end of 2005.
The Division won business from Valeo Electronics &
Connective Systems and from P.S.A. for the development
of TPE Végaprène® wire sealings on the engine. The use
of these sheaths is generalized on platform A (7,000
vehicles per day). This solution incorporates fixation on
the polypropylene housing, a bi-component and complex
part under industrial protection.
Other applications for the fuel circuit and engine cooling
market segments are under current review.
2
21
AEROSPACE-INDUSTRY
BRANDS/COMPANIES
MARKETS
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Barry Controls
Claropan
Deutsche Hutchinson GmbH
Espa
Fit Profilés
Hutchinson DFM
Hutchinson Industries Inc.
Hutchinson SNC
Hutchinson Srl
JPR
LJF Mastics
LJF Stillman
Paulstra
Paulstra Silentbloc
Stillman Seal
Stopchoc GmbH
Stopchoc Ltd.
Vibrachoc S.A.
Aerospace
Automotive:
Body and interior
Construction and public works
Defense and security
Energy, chemicals
Food, agriculture,
and fishing industry
General industry
Health and safety
Home appliances
Mail-Order
Marine
Mass distribution
Railways
Sports and leisure
Transportation
The year 2004 has been a good year for the
Aerospace-Industry Activity.
For the Paulstra Antivibration Aerospace & Industry
Department, 2004 was especially significant due
to an order from SATCO Shanghai, the Alstom partner
in China, to supply primary and secondary pneumatic
suspensions for 28 subway trains of the Shanghai
Yangpur line. Following this first contract, a second was
signed for secondary suspensions of the Canton subway,
a Siemens production and which now fully justifies
the opening of a production site in China.
•
PRODUCTS
SITES
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Antivibration bushings and
couplings
EMI and absorbent coatings
Foam rubber sheets and blocks
Hoses and assemblies
Illuminated panels
Noise and vibration reduction
products
Passive and active suspension
systems
Run-flat and security products
Seals for the aerospace
industry
Profiles for the construction
industry
Tires for two-wheelers
Body parts
•
•
•
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Brazil
China
Denmark
France
Germany
Italy
Netherlands
Norway
Portugal
Spain
Sweden
Switzerland
UK
USA
For Barry Controls Aerospace Department, 2004 was an
exceptional year with a brilliant technical and commercial
success, both for the OEM market and after-market
segments:
Barry Controls supplied the first prototypes for the APU
support on the new Airbus A380 super jumbo.
BCA won business for:
Supplying the complete engine suspension system for
the new Eclipse Mini Jet from a technically innovating
concept based on connection/clamps integrated mounts.
Prototypes were developed in record time and an aircraft
with this fitting on board had a successful flight on
December 31, 2004.
Supplying a hydraulic-suspension system of the HTCS
type for the Chinese Y-8 turbo-propulsor.
Supplying the engine connection system for the new
A400M European military aircraft. Following 3 years of
technical discussions, Barry was able to offer a solid and
complete engine mounting system, meeting the powerful
engines requirements, while satisfying demanding
requirements in terms of strict weight, maintenance
and cost requirements.
Complete maintenance of the engine connection systems
for the MD80 and for the Alaska Airlines Boeing 737
aircraft fleets.
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Sales
Production
An APU A380 mount support element.
WITH HUTCHINSON,
FLY IN AN A380!
▼
Barry Controls Aerospace
has been selected to
supply all the supports
of the A380 Auxiliary
Power Unit. This kit
includes 7 parts
of a 12 kilos total weight
to support the largest
APU ever built and of
more than 600 kilos
weight. We are part
of the production
of a jumbo jet.
BUSINESS ACTIVITIES
1 The Eclipse. 2 The Falcon F7X. 3 and 4 Primary and secondary suspension for the Shangaï, Yangpur line subway.
1
2
On the helicopters market segment, Barry Controls has
successfully continued developing the new damper for
the Bell H1, and the Boeing’s Chinook CH 47 bearing.
The firm has developed and supplied in record time new
Lead-lag dampers for the new Bell (MAPL) module
helicopter.
In addition, a new workshop was built and installed by
BCA for the on-board electronic equipment
mounts/supports for the US market.
Developments were achieved through performance
optimization of the subway intercommunication gangways,
in partnership with Paulstra, and through complex
supports structures used for the transport of EADS
missiles.
Bezons experienced a significant increase of
the aerospace market segment.
In the Aerospace Sealing Department, JPR enjoyed
a significant growth. 2004 was the year of qualification
regarding all the parts in the Airbus A380 and the
Dassault F7X programmes.
Designing and manufacturing reinforced composite
materials parts was continued (A 380 door flaps,
the CRJ200 Bombardier visor tail).
JPR was granted the EN9100 qualification and confirmed
its position in the United-Kingdom with AIRBUS and Rolls
Royce.
Le Joint Français in Roubaix supplied the first delivery of
intercommunication gangways for the Paris and Mexico
City subways.
3
In the Fluid Transfer Systems department, Espa
obtained successful results on the aerospace market with
new products for air conditioning systems: light-weight
hoses and mufflers. Going to the industrialization phase
for the flexible high temperature decouplers of
the aerospace and industry market segments entailed
extending the Fleury Les Aubrais site. Construction work
on a larger design research office and production
department surface area will be completed during 2005.
Hutchinson TFI initiated the industrial mass production
of silicone hoses for the automotive market segment
during Q2 and won new orders of corrugated hoses
for turboenvironnment for the European markets.
On heavy-duty vehicles, a marketing effort was carried out
in the USA with supply of the first decoupler prototypes.
Growth continued in the railways business.
The gas hoses assemblies production from the Joué-lesTours site was transferred to Persan during the summer
holiday period.
Major modernization work was initiated at the 40 m
workshop during Q1 and will be over in 2006.
4
23
5 The Rock Monster, the US four wheel drive mobility truck.
6 Aluminum frame with polypropylene and Vegaprène® sealing profiles and pareclose.
7 Radiotor grille for the phase 2 Renault Mascott.
6
5
The Defense and Security department once again
experienced strong growth in 2004 in the United States,
and growth in Europe.
In the USA, Hutchinson benefited from the production
expansion for vehicle programme, Stryker, supplying
complete pre-assembled VF1/aluminum wheels and VF1
run-flat tires for Hummer vehicles.
A new production process had to be set up in the Trenton
and Persan sites to face a higher sales volume.
Rock Monster was also launched for the American
four wheel drive vehicles.
The Rodgard polymers and thermoplastic resins
production activity also experienced strong growth,
starting with sales of technical products for heavy-duty
vehicle equipment manufacturers.
In Europe, new business was won in France with
finalization of the equipment contract on vehicles for the
Gendarmerie Nationale fitted with the CRF run-flat tire.
In Germany, the activity was maintained through various
contracts for peace-keeping and reconnaissance vehicles
– the LUVW Daimler Chrysler contract – Mungo, Dingo I
and II from Krauss Maffei contracts – Piranha III contract
from Mowag....
This year also experienced a steady growth of the new
generation IRF run-flat tire which meets the requirements
for vehicle weight reduction.
24
The Tires Department once more evidenced its creative
ability with a greater than 50 percent renewal of
its product range in 2004, both for the road and the MTB
market segments. This represents no less than 105 new
product references ! There are three versions of the MTB
tire (Maximum Rebond Control): “Low, Medium and High”
for the entire range. Thanks to this concept, wheel hop
is controlled and the tire grip is maintained. Users can
select which one, depending on how they wish to use and
control the bike.
Six-time consecutive winners of the Tour de France race,
Hutchinson and Lance Armstrong, distinguished
themselves in history. Bettini won the World Cup race
for the third time.
With a Tuning “look”, Kwarter is confirmed as the scooter
tire of choice for teenagers.
In 2004, the Fit Profilés department celebrated with its
personnel 80 years of activity based on innovation and on
market diversification in the construction, automotive
equipment and industrial sectors (household appliances
included).
The company experienced further growth in
construction business, its leading sector, and on tighter
partnership with the automotive equipment suppliers.
Two innovative technical products contributed to the
growth: the cellular TPE profile for woodwork; and, TPE
windshield seals, principally for the new PSA 407 vehicle.
The “Vegaprène®” mixing line represented the major
investment item with new production capacity of “pilot
line” quality for developing formulations for customers’
applications within various departments of the Hutchinson
Group.
“Safety” oriented results displayed a 50 percent reduction
of vocational hazards thanks to the involvement of
personnel on fundamentals. The progressive replacement
of a silicone-based emulsion by a water-based varnish,
Tekskin®, exemplified the approach initiated on
sustainable development.
In 2004, the Sealants, Adhesives & Coatings
department turnover increased in the three market
segments: aerospace, insulation and automotive.
The aerospace sector has benefited from the growth in
production from EADS, on the Airbus in particular.
This trend will be amplified in 2005, now that EADS has
planned a 30 percent increase of the Airbus production
level in 2005 over 2004.
The Department finalized with EADS qualification of
the polyvalent, low density sealant, PR 1782, for use on
the new Airbus 380 which will be later generalized to all
other aircraft in this range. Qualification from this same
customer was also awarded for a range of polysulfide
caps for rivet release, the sealant being more easily
applied by all operators.
Concerning insulation, the Department continues
to develop its Pilkington sales with the major worldwide
glass makers (St-Gobain, Glaverbel and Pilkington) and
the large double-glazed window suppliers. Beyond Europe,
the objective is to supply China, Japan and the
Middle-East. These are countries where sales were
initiated in 2004 but will undoubtedly be developed
thanks to local production, especially in Asia. A new
polyurethane-based sealant was successfully launched
on the market. Its properties make it a less constraining,
easier to apply product than others sold previously,
which greatly facilitates its use.
In the first assembly automotive sector, the Department
started the production of inflatable-sealant for acoustic
parts for assembly of the Fiat Idea and Musa, the Smart
Forfour and the Mitsubishi Colt by Nedcar (Daimler
Chrysler). In addition, the development of the parts for
the new Fiat Nuova Punto was started. A production line
will be started in July, 2005 for 450,000 cars/year. New
business was awarded for the Brazilian version of the
Formore Smart car. The production of prototypes and
tooling was initiated in Brazil.
The Department has completed all qualification work on
these types of products for BMW, Daimler Chrysler, PSA,
etc. Production in the countries where car manufacturers
have their business and plants (Poland, China, Japan, etc.)
can start.
Other automobile business won for first assembly:
• qualification of a bi-component structural glue
(TS 6015/2) for RVI/Volvo for assembly of the Magna
cabs and vehicle tail gates or any other car part when
composite/composite (SMC/ABC, polyester/polyester)
is assembled. This product is currently used in France,
Italy and Germany.
• in the repair market segment (gluing of fixed glazing
and body sealing), which is quite a substantial market
segment (40% of the total Auto market), our sales
in the USA recorded a significant increase thanks to
business won from a second large American glassmaker. North America has become the number one region
using the Totalseal Auto range for professional users,
a very substantial potential growth market in 2005.
In Europe, a major success was reached by the
agreement signed with Fiat as worldwide supplier for daily
delivery of repair parts (Fiat Ricambi) beginning February,
2005.
The automotive equipment market segments (both first
assembly and repair) should continue to grow through
local production in China for supply to Asia (year 2005
programme).
BUSINESS ACTIVITIES
7
A significant increase of the Body Parts department
turnover was noted in the automotive and heavy duty
equipment activities: 5 new products were launched
at the site between January and June, 2004.
Progression in the automotive equipment activity
is essentially due to the new Opel Tigra Twin-Top bumper
production.
Investment on this market segment was initiated with
a view to environmental protection.
• The part surface cleaning is done by means of a “Plasma”
process, no longer using an acid bath.
• A water purification station for water processing was built.
25
CONSUMER PRODUCTS
MARQUES / SOCIÉTÉS
MARCHÉS
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Billy Boy
Blausiegel
Calypso
Facel
Frömms
G-Vir
Mapa
Mapa Professionnel
Mucambo
Nuk
Söke
Spontex
Tigex
Virulana
Baby care
Body care
Dishwashing
Floor cleaning
Hand protection/consumer
markets
Hand protection/professional
and medical markets
Health care
Scouring
Wiping cloths
Organized into three main lines – Homecare, Baby
Care and Health Care – the Hutchinson Consumer
Products Activity followed its strategic actions based
on innovation, internationalization, and an in-depth
knowledge of consumers and customers.
•
PRODUITS
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IMPLANTATIONS
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•
•
•
In the wake of the German event in 2003 and with a wish
to maintain their reputation as an avant-garde firm, Mapa and
Spontex organized a new Fashion Show at the Paris Palais
de Tokyo museum in July 2004. This fashion show was set
up with clothes made from Mapa and Spontex products only
and designed by a highly reputable design school.
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Argentina
Austria
Brazil
Czech Republic
France
Germany
Hong Kong
Hungary
Italy
Malaysia
Mexico
Poland
Slovakia
Slovenia
Spain
Sri Lanka
United Kingdom
Uruguay
U.S.A
Bath and body care sponges
Bottle nipples, pacifiers, baby
bottles, accessories for infant
feeding, breast- feeding
systems
Condoms and lubricating
products
Consumer and professional
wiping products (textiles/
nonwoven/micro-fibres/
sponge cloths/sponges)
Gloves for professionals
Household, gardening,
DIY gloves
High added value medical and
surgery gloves
Infant toys, accessories to help
awaken the infant’s mind,
enhanced safety, baby and
mothers cleaning and care
Laundry products: ironing
boards and covers, moth
repellent
Scouring products for
consumers and professionals
Solid dishwashing product
In the field of Homecare, the Mapa and Spontex brands
breathed new life in France into homecare products and
tools thanks to various new products:
Two new references were added to the Vaisselle Express
product line, Pamplemousse Rose (Pink Grapefruit) and
Peaux Sensibles (Delicate skin). Launched in 2003
Vaisselle Express – the first “solid” dishwashing product
on the market – is available in a solid dispenser so that
the homemaker is able to rub a sponge over the product
without having to put the dishes or sponge down.
Humorous advertising on television – the third arm –
supported the product during 2004 in the Spontex
tradition.
On the Scouring product market segment, Spontex has
the lead by far, with almost 40 percent market share in
value; the innovation policy was continued with the launch
of Origine Coco, an original combined sponge scourer
incorporating coconut hull fibers in the scouring side for
a nature-friendly and efficient result. Mini’s, the “minisponges” for “mini-dishwashing” and Spirjett, the first
disposable spirals on the market, added to the 2004
Spontex range of scouring products.
Mapa continued to go for new market share for gloves,
targeting in particular the younger generation segment
thanks to two new clever and catchy, and well pricepositioned products: Grippy (pearly blue household gloves)
and Granity (a bag of 10 disposable gloves with grip).
Spontex was also one of the first suppliers to launch
a melamine foam-based tool: Effacenet, a revolutionary
product which removes, with no effort or detergent, all
marks and lingering stains (felt-tip markers, ink, etc.).
26
❏
■
Sales
Production
NUK First Choice range of products.
WITH HUTCHINSON,
A “NATURAL” FEEDING
BOTTLE FOR BABIES!
▼
NUK First Choice is
a new bottle and nipple
system. The nipple
features an orthodontic
shape, offering an extralarge support for the lips.
When the baby is nursing,
this minimizes the amount
of air swallowed.
Mothers can use it during
and after the period
of breast-feeding, and
a feeling of well-being
is fostered just like when
the baby was breastfeeding. The bottle mouth
is very wide, which makes
it easier to use and clean.
1 Inauguration of the Virulana workshop in Garin, Argentina. 2 Calypso body sponge.
1
Mapa Spontex duly celebrated the anniversary of
Gratounett, the famous red scouring sponge, as
the number one in sales in this category for the last
20 years. The special edition, dusted gold-spangled
sponges achieved considerable success in France,
showing the brand’s strong reputation in this country.
Following the December 2003 opening of Halaszi
(Hungary), Mapa Spontex inaugurated in March 2004
a new production and conditioning plant for combined
polyurethane sponges in Garin (Argentina). Secure in
the strength of this new industrial tool, Mapa Spontex is
reinforcing its position in the combined scouring market
segment in the Mercosur region with the launch of a wide
range of sponges in Brazil, Argentina, Uruguay and
Paraguay. This strategy perfectly meets the expectations
of quality and value-for-money for the price-conscious
Latin American consumers. Again, in combined
polyurethane scouring sponges, Spontex simultaneously
launched “Wow ! No Scratch” in the USA, a combined PU
product with absorbency properties similar to those of
cellulose. As for Polish and Czech consumers, they can
buy off the shelf a new combined, lemon-scented sponge,
obviously a new Spontex scourer.
2
In China, where the ideogram representing the Spontex
brand mean “comfortable help”, a full range of Homecare
and Bodycare products was launched, actively supported
by demonstrators at point of sale in major customers.
BUSINESS ACTIVITIES
3 Wow and Scour Max, PU scourers for the US market.
For Mapa Professionnel, 2004 was the year of Ultrane.
Developed as hand protection against mechanical
aggression while offering optimal precision of hand and
finger movements, the Ultrane textile-based line of gloves
now includes three new references of nitrile foam-coated
gloves. Whilst offering an excellent resistance to abrasion,
the nitrile-based foam leaves more freedom to the hands
and gloves and are less slippery than with conventional
nitrile enduction. Organized into three families of products
– Ultrane Classiques, Ultrane Plus and Ultrane Grip –
the Ultrane line has now, more than ever, become the
vehicle for progress for Mapa Professionnel.
3
In Asia, Spontex has extended its reach with a product
line in the largest national and international accounts in
Malaysia, Thailand and Singapore. An innovative
programme of special promotional activity was established
in the region to boost market share growth and to
increase brand awareness. Household-related contests
were organized in front of Malaysian and Thai
supermarkets. In another example of innovative promotion,
Bangkok police stations, located at those highly
congested crossroads, were cleaned at peak traffic times
with Spontex home care products by a team of product
representatives. This event was broadcast on national
television and in the press. Spontex mops, sponges,
scourers and gloves were in the limelight as up to date
product leaders in the region.
27
4 The Tigex air humidifier. 5 G-Vir gloving system.
4
On the Baby Care side, the NUK brand is actively present
in 80 countries and has recorded a day-after-day
strengthening of its position as world market leader in
baby and infant care. The new adjustable First Choice
(breast feeding, nipple and bottle system), already highly
successful in Germany in 2003, was a “success story”
in France in 2004. An innovative learning cup with a TPE
wide mouth fosters a feeling of well-being when the baby
is feeding. The First Choice range was launched around
the world and was heartily welcomed by mothers, by the
retail sector and by experts in infant nutrition. In various
target markets, South Africa for instance, the First Choice
system was awarded the Prize for the best feeding bottle
by the local leading “Baby” magazine. In pacifiers, Nuk
launched the Trendline range featuring an orthodontic
shape characteristic of the Nuk brand, shimmering colors,
a transparent material and innovative design. Despite
the competitive pressure and the increased importance
of brands, Trendline has rapidly become the market leader
in Germany and is ready for launching worldwide.
Nuk also developed a TPE disposable, ready-for-use
nipple for maternity hospitals and clinics. The production
process – from mold injection to packaging in flexible
blister packs – is carried out in a clean room, nipple
handling being performed by a 6 (rotation) axis robot.
Allègre Puériculture successfully launched the new
Prodigio brand in 2004, one of the leading products being
the air humidifier to help the baby in fighting against
bronchiolitis. Prodigio is dedicated to specialty stores and
pharmacies. In parallel, a dedicated “professional medical”
sales force for pharmacies, maternity hospitals and clinics
was set up to develop our brands’ presence in these
segments.
Tigex also extended the scope of its licences. Already
holder of a right to use the image of various Disney
characters, Tigex received in 2004 a new licence for
Winnie the Pooh, a success with the younger ones and
their mother. 2004 was also the start-up year for Tigex
in the USA, a country-specific packaging for a line of
products was launched and first listings in dedicated
distributor segment were a success.
28
5
In condoms, Mapa Germany rationalized the market with
three consumer-oriented concepts: Billy Boy positioned in
the “Fun” segment, Fromms as “traditional” and Blausiegel
as a “specialty” product. Thanks to its brand awareness,
Billy Boy extended in 2004 its market coverage to bath
products with under-license launches of a shower gel, eau
de toilette and body lotions. Billy Boy also strengthened
its international position and awareness in Spain and in
Greece through a huge communication effort, e.g.
the “Tour verano 2004” in some famous Menorca discos.
In the health segment via the Hutchinson Health Care
subsidiary, Hutchinson launched G-Vir in 2004, the first
surgical glove to reduce the risk of HIV and HVC viral
contamination in the event of a blood exposure accident.
After more than 10 years of dedicated research and
development, 2004 was the year of the product’s clinical
validation and official launch on the French market.
An article published in a first rank scientific journal was
used as support at a press conference organized on June
17th for the launch. Many press articles in professional
and consumer magazines followed. A marketing team for
promoting and selling the gloves in hospitals was set up,
the aim being approval and referencing of the product in
the major hospital centres. At the end of last year,
the market widened to dental surgeons, a profession
highly exposed to accident hazards.
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Automotive:
Fluid transfer systems
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Sealants, adhesives & coatings
O-Rings
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Body parts
Spare parts
Industry:
Antivibration aerospace system
Defense & industry vibration isolation
Control & display systems
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Sealing, fluid transfer systems
Transmission systems
Precision molded parts, flat seals
O-Rings
Foam and converting products
Profiled seals for construction
Sealants, adhesives & coatings
Professional gloves
Consumer Products:
Household gloves
Sponges
Household products
Baby care products
Tires
Health Care:
Condoms
Surgical gloves
Design: wprintel + Atelier Takavoir
Art production: wprintel
Photo credits: Thierry Dehesdin,
Ed. King, Xavier Lefèvre, Marina Raith,
Néovision/Photonica, PSA Peugeot Citroën,
Communication Departments / Stéphane Muratet,
© Airbus s.a.s 2005 Computer modeling
& rendering Abac effect s.a.s,
© Olaf Tiedje/Photonica.
Head Office
124, avenue des Champs-Élysées
75008 Paris / France
T. + 33 (0)1 40 74 83 00
F. + 33 (0)1 43 59 97 11
www.hutchinsonrubber.com
[email protected]
Limited Company
registered capital €42,411,960
R.C.S. Paris B 542 051 826