1. Improving.ABB Robotics Productivity Division Overview Process Quality Workplace Safety ABB

2. Facts about ABB A leading power and automation Headquarters: Zurich, Switzerland technology company with strong More than 110,000 employees inmarket positions in core businesses about 100 countries We help our customers: Orders in 2007: $34.3 billionto increase industrial productivity Revenues in 2007: $29.2 billionto use electrical power efficiently Listed on Stockholm, Swiss & Newto lower environmental impact in a York exchanges; traded on virt-xsustainable way ABB Robotics - 2 3. What we offer: divisional structure and portfolio2007 revenues (US$) and employees per division Power PowerAutomationProcess RoboticsProductsSystemsProductsAutomation$9.8 billion$5.8 billion$8.6 billion$6.4 billion$1.4 billion32,000 employees14,000 employees33,000 employees26,000 employees 5,000 employeesTransformers, high- Substations, FACTS, Low-voltage products, Control systems andRobots, peripheraland medium-voltageHVDC, HVDC Light, drives, motors, power application-specific devices and modularswitchgear, breakers, power plant & network electronics, andautomation solutions manufacturingautomation relays automationinstrumentation for process industries solutions for industryMarket-leading positions in most key product areasIntegrated solutions for grid reliability, productivity and energy efficiency ABB Robotics - 3Robust global value chain to serve established and emerging marketsExtensive global network of value-added channel partners 4. Overview Agenda Robotics DivisionMarkets ServedProducts & Systems offerService offerSummary ABB Robotics - 4 5. Robotics divisionMarkets served Automotive and their Tier 1 suppliers General industries including foundry, metal fabrication, plastics, consumer electronics, food & beverage, machine tools, solar, pharmaceuticals & chemicals, woodKey deliverables Robots, application equipment and software Standardized manufacturing cells for material handling, machine tending, welding, cutting, painting, finishing, etc. Engineering for systems in press automation, body-in-white, paint processes, power train assembly ABB Robotics - 5 Product & systems service 6. Robotics division - key facts 2007 Orders $1.6 billion 5000 employees in over 45 countries Manufacturing in 3 regions, Europe, Asia & America Sales & Service operations in over 45 countries & over 100 locations Introduced painting robots in 1969 and the worlds first commercially available electric robot in 1974 Over 160,000 robots installed worldwide at end 2007 ABB Robotics - 6 7. Two channel market approach Customers & Users Direct salesIndirect sales Channel Partners-System Integrators -Machine builders (OEMs) Robots, Robot Cells, Systems, Service ABB Robotics - 7 8. Global Partner Program in robotics Global program for System Integrators and Machine Builders Robot integration on 3 levels, Partner, Preferred Partner & Strategic Partner Benefits of ABBs Partner ProgramPartner agreementInvitation to Partner SeminarsPremium Partner WebImage & VisibilityPartner symbolsPartner reference storiesExhibitions & SeminarsSales material ABB Robotics - 8Demo robots & cellsSales support & training 9. Global Reach, Local operations ABB Robotics - 9 Present in 45 countries - in more than 100 locations 10. Experience from 160,000 + robot installationsOther processesand assemblyArc welding PaintingMaterial handling &Spot weldingMachine tending ABB Robotics - 10 11. Continuous technology developmentJoystick motion control MultiRobot controlS2 Robot Controller TPU MultiMove Hydraulic paint robot Electric Paint Robot Modular Controller Trallfa TR-200 TR5400 Touch screen HMIIRC5 controller6 axis electric robotIRB90High-speed Picker IRB340 FlexPicker Open ArchitectureS4 Controller 1970 198019902000 AC Servo Drive systemIRB2000Arc weld processsimulationVirtualArcFirst electric robotModular DesignASEA IRB6 IRB6000 range 500kg robot ABB Robotics - 11 IRB7600 Dynamic Motion Control TrueMove, QuickMove Offline Programming & Simulation RobotStudio 12. Continuous technology development Hydraulic paint robot 6 axis electric robot Joystick motion control Trallfa TR-200IRB90 S2 Robot Controller TPU 1970 197519801985 1990 ABB Robotics - 12 First electric robotAC Servo Drive system Modular Design ASEA IRB6 IRB2000 IRB6000 rangeInnovation & technology are part of our DNA 13. Continuous technology development Open ArchitectureHigh-speed Picker MultiRobot controlForceControl S4 ControllerIRB340 FlexPicker MultiMove FC MachiningModular ControllerFC Assembly Touch screen HMIIRC5 controllerElectric Paint Robot TR5400 Process Arm for AW IRB1600ID1995 2000 2005200620072008 Dynamic MotionArc weld process 2nd Generation Next Generation Control simulation Motion control Safety Systems TrueMove, QuickMove VirtualArc TrueMove, QuickMoveSafeMove ABB Robotics - 13 Offline Programming &500kg robot Compact paint robot Simulation IRB7600 IRB52 with integrated IPS RobotStudio 14. The top 10 reasons for robot investment Increase production output ratesReduce operating costsImprove process qualityImprove workplace health & safetyIncrease product manufacturing flexibilityReduce material waste and increase yieldReduce labour turnover and difficulty of recruiting workersSave space in high value manufacturing areasReduce capital costs (inventory, work in progress)Improve quality of work for employees ABB Robotics - 14 Based on research carried out by the International Federation of Robotics (IFR) 15. Overview AgendaRobotics Division Markets Served Products & Systems offer Service offer Summary ABB Robotics - 15 16. Segments Served - Overview MetalFood &AutomotivePlastics Foundry Fabrication BeverageChemical & Consumer Machine Tools Wood SolarPharmacy Electronics ABB Robotics - 16 17. Automotive Industries Overview Markets & applications served Automotive components Powertrain assembly Press automation Paint process automation Body-in-whiteCustomer needs Cost competitiveness Higher production outputs Zero defects Capacity to meet continued growth in demandABB Offerings Industrial robots with integrated application software Fully engineered systems & cells Vision guidance systems Service agreements & productivity improvement Simulation & offline programming software ABB Robotics - 17 Easy to use operator interfaces 18. Plastics Industries OverviewMarkets & applications served Automotive, electronics, medical, household goods, Machine tending in injection moulding, blow moulding, thermo forming Water-jet, laser, ultrasonic and mechanical cutting Dispensing, gluing and foaming, painting Assembly, flame treatment and painting Customer needs Increased quality & reduced cycle times Flexibility to accommodate short run production Added production value to secure producers margins Reduction in direct & indirect labor cost Improved Health & safety ABB Offerings Robots, cells & systems via ABB & selected partners Easy to use operator interfaces Simulation & offline programming ABB Robotics - 18 Service agreements & productivity improvement 19. Foundry Industries Overview Markets & applications servedSand casting, Gravity casting, Precision castingDie castingForging & Lost foamHandling, Machine Tending, Casting cleaningQuality control, Surface treatmentCustomer needsPrecision and improved process controlImproved Health & SafetyReduce of waste and increased yieldImprove uptime, energy efficiency and productivityABB OfferingsIndustrial robots for handling & finishingCells & systems via ABB & selected partnersGlobal solutions for vision & machiningService agreements & productivity improvementSimulation & offline programming software ABB Robotics - 19Easy to use operator interfaces 20. Metal Fabrication Industries Overview Markets & applications servedAgricultural, furniture, vehicles, white goods,2-wheelers, construction equipment, trains, shipsCutting, Welding and JoiningForming, Inspection and MeasuringMaterial handlingSurface treatment, Finishing, PaintingCustomer needsGlobalization and consolidation within the industryHigh quality, capacity & efficiencyAutomation due to shortage of skilled manual workersImproved Health and safetyABB OfferingsIndustrial robots & application equipmentSystems & cells via ABB and selected partnersStandardized arc welding cells (FlexArc)Service agreements & productivity improvement ABB Robotics - 20Simulation & offline programming softwareEasy to use operator interfaces 21. Food & Beverage Industries Overview Markets & applications servedFood, beverage, pet-food, tobaccoPackaging, confectionaryPicking, Packing, PalletizingCustomer needsSpeed of deliveryProlonged shelf life of productsShorter product lifecycles, new packaging designsand product variantsIncreased uptime, yield & zero breakagesImproved Safety and HygieneABB OfferingsRobots for picking, packing, palletizingSystems, cells & solutions via selected partnersService agreements & productivity improvementSimulation & offline programming softwareEasy to use operator interfaces ABB Robotics - 21Vision & cell integration software 22. Chemical & Pharmaceutical Industries Overview Markets & applications servedPharmaceutical Drug Discovery & ProductionChemicals, Medical DevicesPersonal & Home CarePicking, Packing, PalletizingCustomer needsFlexibility to handle different pack & product variantsQuality validation & traceabilitySuitability for sterile production environmentsIncreased yyieldABB OfferingsRobots for picking, packing, palletizingSystems, cells & solutions via selected partnersService agreements & productivity improvementSimulation & offline programming softwareEasy to use operator interfaces ABB Robotics - 22Vision & cell integration software 23. Machine Tool Industries OverviewMarkets & applications servedPrecision machining including turning, milling,grinding, drilling, Machine tending and handlingQuality control, InspectionSurface treatment & part finishing Customer needsAutomation due to shortage of skilled workers &rising cost of laborFlexibility to accommodate short run productionConsistent high part qualityImprovements in uptime and productivityImproved Health & safety ABB OfferingsIndustrial robots for machine tending and postprocessing (multiple tasks)Easy to use operator interfacesDedicated machine interfaces ABB Robotics - 23Simulation & offline programming softwareService agreements & productivity improvements 24. Wood Industries Overview Markets & applications served Wooden furniture, flat-pack, doors, windows, wood for building construction, kitchens Handling, machine tending, painting, packaging, finishing, palletizing, sanding, carvingCustomer needs Automation due to shortage of skilled workers / rising cost of labor Consistent high part quality Improvements in uptime and productivity Health & safety improvements Better utilization of high cost machineryABB Offerings Industrial robots & selected application equipment Easy to use operator interfaces Vision guidance systems Simulation & offline programming software ABB Robotics - 24 Service agreements & productivity improvements 25. Consumer Electronics Industries Overview Markets and application servedComputers, mobile phones, digital cameras,media players, games consoles, camerasLaser welding, painting, grinding & polishingExtraction, spraying and tending for die-casting andinjection molding machine cellPalletizing/de-palletizing, assembly, picking &packingCustomer NeedsQuality, precision and cosmetic finishShort cycle time and high volume productionShort product life cycle production runsRising cost of labor and demanding H&SSimple compact & flexible solutionsABB OfferingIndustrial robots and application equipmentPaint application systems ABB Robotics - 25Grinding & polishing systems (Flex-finishing)Service agreements & productivity improvementsSimulation and off-line programming software 26. Solar Photovoltaic Industries Overview Markets & applications served Solar Photovoltaic power generation Solar cell and module production (silicon and tf) Material handling (ingots, wafer/cells, modules) Module assembly, e.g. soldering, edge trimmingCustomer needs Increasing production capacity and efficiency Reduction of production cost Constant high product quality output Standardization of production plans worldwide with high-end, flexible automation/roboticsABB offerings Industrial robots for all applications including Clean Room Class 5 Standardized ABB function packages for cell- and module manufacturing Simulation & offline programming software ABB Robotics - 26 Service agreements & productivity improvement 27. Other Industries Served Building MaterialsDefense & AerospaceGlass productsSanitary/Tableware/Ceramics ABB Robotics - 27 28. Overview AgendaRobotics Division Markets Served Products & Systems offer Service offer Summary ABB Robotics - 28 29. Robots & Systems overview ApplicationManufacturingAutomotiveRobotsSoftware Equipment CellsSystemsComprehensive rangeFully integratedController & PCModular Fully engineered of small, large, paint & process equipment based software tomanufacturing cells automotive systems dedicated robots withfor arc welding,support robots & based on globally for BIW, Paint, handling capacityhandling, spotwelding systems throughout proven solutions. Powertrain & Press from 1kg to 650 kg and paintingtheir entire life-cycle. Tailored to local needs automationMarket-leading positions in key areas Integrated solutions for productivity, process control & workplace safety ABB Robotics - 29 Global coverage serving established and emerging markets Extensive global network of channel partners 30. ABB market offer: Robots Robots and robot controllers Application equipment ABB Robotics - 30 Software 31. Industrial Robots - Overview Picking Packing Palletizing6 axis Robots Paint RobotsDedicated 4 axis Robots Comprehensive range from 1kg to 650kg payload capacity Robust, Rigid, Reliable, Easy to Use ABB Robotics - 31 Customization through modular design concept Protection with Clean Room, Foundry Plus & Foundry Prime (IP67), Wash Down 32. Small Robot family: Pay load 5 kg to 60 kg IRB140 IRB1410 IRB16006kg0.81m 5kg 1.44m 6-8.5kg 1.2/1.45mIRB4400IRB2400 IRB1600IDIntegrated Dressing ABB Robotics - 3210-60 kg 1.95/2.55m 5-20kg 1.5/1.8m4kg 1.5 m 33. Large Robot Family: Pay load 90 kg to 650* kg IRB6620IRB6660 Pre Machining IRB6660 Press Tending150kg2.2m 205kg 1.9 m 130kg 3.1m IRB6650SIRB6640 IRB7600 * 650kg capacitywith wrist down ABB Robotics - 33 90-200 kg 3.0/3.9m130-235kg2.55/3.2m 150-500kg 2.55/3.5m 34. Painting Robots: with dedicated controller IRB52IRB540IRB580/58 Compact Paint Specialist Flexiwrist & CP program Hollow wristIRB5400IRB5500 IRC5Paint ABB Robotics - 34 Process or Slim Arm Car Body PainterDedicated Paint Control 35. 4 axis Robots: Picking, Packing, Palletizing IRB360 FlexPicker IRB260IRB660 High Speed Picker Top loader/Packer Palletizer 1-3kg 1.13m30kg 1.5m 180-250kg 3.15m Serving fully integratedpacking lines ABB Robotics - 35 36. Robot controllersModularPanel mounted Dedicated paintGraphical userversionsversion version interfaceMulti-robot control, up to 36 axis, with MultiMove Programmable user interface with joystick motion control with FlexPendant ABB Robotics - 36 World leading motion control with TrueMove & QuickMove Next generation safety with SafeMove Powerful connectivity through network interfaces 37. Application equipment Paint Process Equipment includingAtomizersIntegrated Process Dress PacksWorkpiece positionersProcess cabinetsArc & Spot Welding processequipmentAdditional axis including tracks andmotor/gearbox units ABB Robotics - 37 38. Software Delivering Power & ValueNothing boosts productivity anddecreases the total cost of owning andoperating a robot based solution more thana ABB Software Package.ABB has developed a family of world classsoftware products to support every stageof the robot life cycle. Benefits include:Reduced risk of operator mistakesLess need for trainingEasy to use operator interfacesApplication customizationIntroduction of programmes & testing offlineVerifying new products quicklyRemote monitoring of productionRemote diagnosis of problems ABB Robotics - 38Easy to use programmer interfaces 39. RobotWare for easy to use interfaces Spot welding & Arc weldingPlastics & DieCastingMachining FC & Machine TendingAssembly & PackagingPress tending ABB Robotics - 39 40. RobotStudio for simulation & offline programmingCreate a common view in the planning stage Verify tooling and fixtures in the design stage Program robots faster in the start-up stage Modify programs without downtime in the production stage RobotStudio is theeasy-to-use, low costsoftware for visualizationand offline programming of ABB Robotics - 40ABB robots. It is the toolyou need to maximize yourproductivity 41. Case Study - From six months to six days The Business Need:A contract manufacturer uses plasmaspraying system to make partssurface heat-resistantOnline programming had beenunsuccessful after more than 6monthsThe customer did not approvethe part quality The Solution & Benefits:Higher part qualityWith RobotStudio the CAD data wasutilized to quickly generatea very accurate programCut programming timeA new program was created withRobotStudio in half a day ABB Robotics - 41ReachabilityRobotStudio showed that the robotcould be placed in a better position inrelation to the part 42. Robot-based manufacturing cells - OverviewSpot WeldingArc Welding Painting/CoatingCuttingPress TendingFinishingMaterial Handling Machine Tending ABB Robotics - 42 43. Global robot-based solutions 2D & 3D Robot VisionGuidance TrueViewStandardised ArcWeldingCells FlexArcMachining Function PackagesMachining FC FunPacStandardized Finishing CellsFlexFinishing ABB Robotics - 43 44. TrueViewTM vision guidance for robotsTrueView is a single camera, 3Dvision guidance system that allowsABB robots to precisely locaterandomly presented & irregular partsTrueView is tightly integrated tothe ABB robotseamless integrationcommon components andintegration methodologystandard robot programmingmodulescomplete documentation forinstallation and servicesRecognized as best in class forsingle camera 3DSpecified at Ford & Toyota ABB Robotics - 44Growing success with Honda (1stinstallations in US and Japan)Over 200 Systems installedglobally 45. FlexArcTM arc welding cellsGraphical interactive HMI on FlexPendantIntegrated weld error recoveryIntegrated production monitoringIntuitive production managerNavigator softwareCell calibrationTooling calibrationPart measurementsCell checkIdentical replicas of all cells available free in digital versions ABB Robotics - 45 46. Machining FCTM & FlexFinishingTM cellsProven solution for roboticgrinding, deburring, polishingand other mechanical finishingprocessesIntegrated package for setup,programming and production Easy to integrate & deploy Easy to use - Plug & Produce Lead by hand programming Easy relocation of cell withinproduction plant ABB Robotics - 46 47. Automotive Systems via Global Lead Centers Press Automation Body in White Assembly Paint Automation Power Train Assembly ABB Robotics - 47 48. Press Automation From stack to rack ... Complete press shop automation ! Loading and unloadingof stampings ABB Robotics - 48Racking of stampings 49. Body-in-White Plug & Produce solutions- from component assembly to body complete ...FlexLean Modular Solutions ABB Robotics - 49 50. Paint Process Automation Flexibility, high quality, low waste - from barrel to surface. Sealing & coatingPaint equipment ABB Robotics - 50 Painting line 51. Powertrain AssemblyFrom assembly of engines & transmissions to full test... consistent quality and just in time! ABB Robotics - 51 52. Automotive Systems customers Automotive Automotive ABB Robotics - 52 OEMsTier One 53. Example of scope of supply in Automotive Trimming and Foam DepositionWater Jet CuttingOver US$ 167 million investment Parts: Car seatsParts: Dashboards Solutions for applying foamin ABB equipment, systems To produce the Megane II car seats, ABB has supplied robotized arc welding cells and trimming plastic parts have been provided for dashboard manufacture. and services Parts: Headliners (J84 version, Turkey)ABB solutions have been installed for different to various plants. applications in the headliner manufacturing process including water jet cutting, handling and gluing.Arc WeldingBody-in-White Robotized Applications Parts: Car body (J84 version) ABB has supplied complete turnkey systems Parts: Headlamps to produce different body parts such as cross- ABB has supplied two robotized cells members, floors, roof cross-members and rearfor headlamp manufacturing. back panels.Paint Process AutomationBody-in-White The Megane II from Renault Parts: BumpersParts: Cross-car beams for dashboard ABB has supplied additional equipment ABB has supplied arc welding and handling to the bumper paint line. turnkey solutions for cross-car beam assembly, which are installed in Spain and France.Body-in-WhiteBody-in-White Paint Process AutomationPaint Process Automation ABB Robotics - 53 Parts: DashboardsParts: Car bodiesParts: Car bodiesParts: Car bodiesA complete paint line for dashboards has beenABB has installed turnkey robotized solutionsABB has supplied body shop solutions for complete bodyThanks to a close cooperation with Renault, Supplied to a Neyr plant in France, which includesto produce underbody parts, cross-members, etc framing and for the assembly of underbody components,ABB has developed complete robotized solutions for cavity paint distribution and robot application.at both Spanish and French plants. complete underbodies and body sides.waxing and has also installed sealing applications. Combined with the equipment, ABB has proposed a system care agreement to support Parts: Exhaust systemsTo adapt the paint lines to the new Megane II,the maintenance of the line. ABB has provided complete assembly shops to French Renault has invested in additional paint equipment and Spanish plants. such as robots and applicators. 1 US Dollar = 1 Euro 54. Overview AgendaRobotics Division Markets Served Products & Systems offer Service offer Summary ABB Robotics - 54 55. Service offer overview A partnership for productivity improvement Parts & Logistics - Spare Parts Sales - Repair Centers - Inventory ManagementPerformance ServicesContracts - Full Service contracts - Total equipment management Field Services- Automation performance management- Service Contracts- Helpdesk & Remote Services- Field Operations- Installation & CommissioningTraining Productivity Improvement Projects- Product and System Training - Asset Re-Utilization- Documentation - Productivity Improvement Software- Consulting ABB Robotics - 55- System Upgrades and modifications 56. Global Service Organisation - 1500 Employees Americas289Europe - MEA1056 Asia- Pacific 171 ABB Robotics - 56 Present in 45 countries - in more than 100 locations 57. Parts & LogisticsOver 20,000 spare parts available Upgrade kits Accessibility 24/7 Inventory managementSmartSparesPartsOnline ABB Robotics - 57Its all about the right part at the righttime at the right place 58. Service Agreements Offering you measurable results Service Agreement Packages from ABB Maintenance PackageMaximize the Mean Time BetweenFailures of your equipment Response PackageMinimize the Mean Time To Repairwhen stoppages do occur Warranty PackageControl the Total Cost of Ownershipof your ABB investment ABB Robotics - 58 Annual or ABB Service Professional Customer Representative Multi-year 59. Case Study Service Agreement Veltri Modular, Canada ABB Solution A 5 Year Service agreement to include: Extended Warranty on Parts/Labor Consignment Parts Tailored On Site Training and Training Credits for scheduled courses 24/7 Technical Support Line Emergency Breakdown Block of Hours Continuous Improvement visits The Business Need Plant Audits Veltri Modular in Windsor, Ontario, Canada wanted aKey drivers & benefits proactive, cost effective way to manage their The service contract provides worry free service support needs.operation of 100+ robots for 5 years They needed to fix theirBy improving the skill set of the employees costs up front and notand the productivity of the manufacturing cells worry about the paying forVeltri production levels improved and they ABB Robotics - 59 each individual service call. now produce a higher quality product They also wanted advice on how to continuallyAll new robots for Veltri will now come with improve productivityan Integrated Service Agreement 60. Certified Refurbished RobotsRefurbishment programs for customer owned equipment Large global inventory of used robot systems Rebuilt to factory specification, using original parts ABB Robotics - 60 61. Our Global Training CentersArgentina Australia AustriaBeNeLux Brazil CanadaChina Czech Republic ABB Robotics - 61Denmark Estonia FinlandFrance 62. Our Global Training CentersGermanyIndiaItaly Japan KoreaMalaysia Mexico Norway ABB Robotics - 62 Poland RomaniaSlovakia Slovenia 63. Our Global Training Centers South Africa Spain SwedenSwitzerlandTaiwanThailand United Kingdom United States ABB has dedicated, professional training centers locatedthroughout the world. No other robot manufacturer has made sucha large investment in equipment (over 300 robots) and professionalinstructors (over 100) that are dedicated, full-time, to the education ABB Robotics - 63 of our customers staff. 64. Overview AgendaRobotics Division Markets Served Products & Systems offer Service offer Summary ABB Robotics - 64 65. Serving our customers business needsIncreased Productivity We help customers improve manufacturing productivity and energy efficiency. Our services build on experience from over 160,000 installations Reduced Operational Costs Our products and services help customers minimize project capital costs and lower The effort of ABB to ongoing fixed costs surpass the original specifications, and their Consistent Process & Product Quality willingness to assist us toRobots are proven to deliver consistent get more & more out of the high quality. They can be recruited to roles system, has been excellent.where skilled staff are hard to find We asked for an output of 9 parts per minute but theImproved Workplace Health & Safety system gives us better thanABB's health, safety, security and 11 Helping minute parts per customers boost ABB Robotics - 65environmental offerings help companies productivity while conserving achieve the highest levels of corporate Colin Thomas, Electroluxsocial responsibility Australiaenergy. 66. We have a passion for roboticsABB is committed to being a world leader inrobotics; capable of designing, producing &delivering the highest quality robots, systems& service to meet the needs & expectations ofour customers.Quality will be built in to everything we doand will be evident each time we deal with ourcustomers.Service is a key part of our offer. We willsupport our customers with the highestquality, most responsive organisation in the Even in very diverse industries, we see industry. common challenges - increasing productivity and quality, keeping pace Technology & innovation are part of our with competitors, and adding flexibility DNA. We will continue to invest heavily in to meet rapidly changing consumerR&D to ensure we meet our customers needs preference.- both today and in the future. ABB Robotics - 66 In both traditional and new industries, ABB robots are busy creating a core competency in bottom line results.Anders Jonsson Head of Division ABB Robotics 67. For more information visit www.abb.com/robotics ABB Robotics - 67