1. The Leader in Lightweight Technology

2. Consolidated Metco Annual Sales FY2002:$238 Million Employees:1,157 Headquarters:Portland, Oregon History –Company roots are in the truck business… Started by Consolidated Freightways-1964 –Freightliner/Daimler Benz 1981 –LBO-1987 –Varlen -1989 –Amsted-1999 ESOP Company with 9 Operating Companies/ $2.1B Sales 50% Ownership in Maxion Brazil (Steel Foundry/ Fifth Wheel)

3. D AIMLER B ENZ

4. Manufacturing Locations Portland, OR 200 Employees 166,000 sq. ft. Clackamas,OR 180 Employees 65,000 sq. ft. Monroe, NC 350 Employees 300,000 sq. ft. Bryson City, NC 165 Employees 182,000 sq. ft. St. Thomas,Ontario Canada 10 Employees 10,000 sq. ft. Monterrey, Mexico 150 Employees 68,000 sq. ft. Cashiers, NC 165 Employees 96,000 sq. ft. Etowah, TN 10 Employees 60,000 sq. ft.

5. Recognized Quality Supplier PACCAR Preferred Supplier Freightliner Masters of Quality Eaton Corporation Quality First Daimler Benz VDA Approved Meritor Preferred Supplier Honeywell Preferred Supplier TS 16949 Monroe, Etowah, Clackamas, Rivergate, Bryson City, Cashiers Approved

6. The Leader In Lightweight Technology

7. Major Processes & Products Aluminum – –Semi-permanent Mold – –Low Pressure – –Die Casting Machining and Assembly – –Hubs – –Fifth Wheels – –Castings – –Fuel Water Separators Plastics – –Structural Foam – –Gas Assist – – Injection Molding – –Thermoforming

8. Hubs

9. Brake Drums

10. Plastics

11. Die Castings

12. Permanent Mold Castings

13. Simplex Fifth Wheels

14. Fifth Wheel Approximately 26,000 units sold per year (15% market share) Standard at Freightliner, Volvo, Mack Two models: Simplex & Simplex II Over 60% of units are sliders Product development includes two new slider models Production located in Monroe, NC Testing and development in Portland, OR

15. Simplex Simplex Fifth Wheels Simplex II Vertical Load Capacity: 50,000 lbs Trailing Load Capacity: 150,000 lbs Vertical Load Capacity: 70,000 lbs Trailing Load Capacity: 200,000 lbs Standard with a left hand, straight pull release Optional Touchloc pneumatic unlocking system

16. ConMet Test Center Capabilities Rotating Bending Hub Fatigue Testing Seal Abrasion Testing Fifth Wheel Vertical and Fore/Aft fatigue testing Fifth Wheel Ultimate Rollover Testing Component Fatigue Testing

17. Hub Fatigue Testing

18. Seal Abrasion Testing

19. Fifth Wheel Fatigue Testing

20. Fifth Wheel Rollover Ultimate Test

21. Rollover Ultimate Test Results

22. Why we test our Fifth Wheels

23. Capstone Project Outline The purpose of this project is to conceptualize, analyze, design and build a test fixture for testing the ultimate strength of heavy truck fifth wheels in the draw bar load case. The purpose of this project is to conceptualize, analyze, design and build a test fixture for testing the ultimate strength of heavy truck fifth wheels in the draw bar load case. This project will incorporate all elements used in Mechanical Engineering from design, analysis (FEA), prototyping (working with local machine designers), and data acquisition.

24. Drawbar Load Case Defined F drawbar = 150K to 200k

25. Drawbar Load Case

26. Capstone Project Outline Conceptualize and Brainstorm design ideas Paper design chosen design Model and Analyze design with Solid Modeling & FEA Perform prototyping (using local vendors) Assemble and build Drawbar Tester (ConMet test lab) Test the machine for proper functionality Perform destructive test and collect results Write report Perform presentation

27. Questions?