7th August 2007 - Lean Manufacturing Beefs Up Raybestos® Brand 1-2-3 Product Strategy

Investment in Manufacturing Cell Increases Output Capacity by 15%

To help maintain current efficiencies and satisfy increased demand generated by its new 1-2-3 strategy, Affinia has invested $3.5 million in an advanced lean manufacturing cell at its Stanford, Kentucky manufacturing facility for Raybestos®  brand disc brake pads.

The new system, designed and produced by Leinweber Maschinen in Austria, is more comparable to OE than traditional batch manufacturing systems. “Lean cell manufacturing gives us the ability to produce the large variety of product our customers need in the abbreviated lead times they have come to demand,” said John Feather, plant manager for Affinia’s manufacturing facility in Stanford, Kentucky.

Feather said there are four priorities when setting up any new manufacturing process for Raybestos® brand products: Safety, Quality, Throughput and Efficiency. “This new process wholly satisfies all four priorities and we expect almost zero defects from the new manufacturing cell.” While the new cell will increase production capacity in Stanford by nearly 15%, it takes up less than 10% of the floor space.

The cell will begin producing parts in September and will be fully functional early in the fourth quarter. Training for those team members working the cell is already underway. “Employees undergo 80 hours of classroom training,” said Feather, “40 hours in teamwork training and 40 hours in lean manufacturing principles.” These same employees then spend an additional two weeks in cell-specific work process training.

In the current “batch type” manufacturing process, disc pads travel through five separate departments over the course of 1,300 feet. In the new lean cell process, the parts travel about 80 feet in less than one hour; including all processes from molding through packaging. The cell includes state-of-the-art equipment including positive mold cure presses, grinding machines, post curing ovens, powder coat paint systems, and CNC controlled hardware attachment machines.

“Our 1-2-3 strategy has been a great success, and the resulting increase in demand for our premium products requires us to find increased efficiencies in our manufacturing processes”, said Bruce Reau, vice president of category management for Affinia Under Vehicle Group. “In utilizing this new lean manufacturing cell, Affinia will increase capacity to produce the latest generation of Raybestos® brand Advanced Technology™ friction formulations, while reducing working capital and distribution costs.”

The lean manufacturing project increases the ability to supply premium disc pad sets at the high level of quality and rapid order fill expected by high volume customers and independent shops, alike. Given the increase in demand for its premium products, the new cell will manufacture 26 of the top selling part numbers within the Raybestos® brand Advanced Technology™ brake pad products.

Raybestos® brand brakes are produced by Affinia Under Vehicle Group, the leading manufacturer of braking systems and components for the automotive industry. The line includes everything from brake drums to rotors, pads, shoes and hydraulic parts. Affinia Under Vehicle Group is at the forefront of research and development in brake technology and operates manufacturing and distribution facilities throughout North America. Raybestos® brand brakes are the official brakes of NASCAR, and the NASCAR relationship also includes the Raybestos Rookie of the Year Award, which is presented to the top rookie in each of the NASCAR NEXTEL Cup, Busch and Craftsman Truck racing series. For more information about Raybestos® brand brakes, visit www.raybestos.com.

Affinia Group Inc. is a global leader in the on- and off-highway replacement parts and service industry. In North America the Affinia family of brands includes WIX® Filters, Raybestos® brand brakes and Aimco® brake products, and McQuay-Norris® and Spicer® Chassis parts. South American and European brands include Nakata®, Urba® and Quinton Hazell®. For more information, visit www.affiniagroup.com