Esys Capabilities Presentation

1. Markets We Serve Our Capabilities
Esys at a glance
• Automotive • Engineering Services
• Integration & Custom Manufacturing
• Logistics Incorporated in 1999
• Defense & Aerospace • Robotic Sealing & Coating Applications
• Government Agencies • Material Handling Solutions
• Low Volume Manufacturing • Custom Machines and Test Systems
75 Engineers on Staff
• Machine rework / retrofit / upgrade / relocate
• Design and build of PLC based control systems Open Book Management / PSP
• SCADA Systems
• Manufacturing Execution Systems (MES) 2008 Revenue Sales of $18 Million
• Tire & Wheel Assembly Solutions
45,000 Sq Ft Facility

2. Engineering Services
Additional Advantages
• 2D to 3D CAD Conversion
Mechanical Engineering
•Pro/Engineer, • Technical Data Package (TDP) Creation
•Unigraphics • Configuration Management
•AutoCAD • Manufacturability Studies
• Requirements & Specification Definition
Electrical Engineering
•AutoCAD • Conceptual & Feasibility Studies
•ePlan • Design for Manufacturing
• Mechanical Design and Analysis
Controls & Software Engineering
• Mechanical 3D Modeling & Detailing
•Allen-Bradley
•Siemens • Electrical Hardware & Software Design
•Mitsubishi etc… • System Integration
• Simulation and Animation

3. Integration & Custom Manufacturing
Additional Advantages
• 25,000 Square feet
Applications Include: Our Capabilities Include:
• 10 Ton overhead crane
• Integration • Supplier maintained inventories
• Ground level bay shipping
•Material Handling Equipment • Scalable workforce
• Dock level bay shipping
•Water Spray Booths • Light machining
• 10K AMP power
•Robotic Cells • Dry Ice blasting & machine cleaning
• Clean power
•Machine Repair, Retrofit, Upgrade • Piping and Wiring
• 62 cfm distributed air drops
• Custom Manufacturing • Pneumatics & Hydraulics assembly
• Real-time webcam monitoring
•Electrical Control Panels • Material management and kitting
• R&D area
•Enclosed Industrial PCs • Extensive Subcontract Network
•Operator Interfaces •Precision Machining
•Pick-bins •Proto-typing
•Custom machinery •Painting & Powder Coating

4. Design & Build of PLC Based Control Systems
Applications Include: Our Capabilities Include: Control Upgrades
• Replace proprietary controls
• Automotive Body Assembly • Allen-Bradley Logix Platform • Common off the shelf components
• Paint Systems • Factory Talk
• Automotive General Assembly • Siemens S7
• Conveyors - Skid, Skillet, P&F, AGV etc. • Siemens WinCC
• Part Transfer Systems • EPLAN
• Stamping & Presses • VFD & Servo Systems
• Waste Water, Water Treatment, RO • Specification & Standards Development
• Complete Panel Build

5. Vision Systems
Applications Include: Our Capabilities Include:
• Part Identification • Interface to PLC & Tooling
• Mistake Proofing • Intuitive Operator Interfaces
• Defect Detection • One Touch Teaching Software
• 2D & 3D Barcode • Image Logging and Reporting
• Assembly Verification • Remote IT Support
• Tire Tread Vision • On-site Support
• Wheel Type Detection • Inexpensive Hardware Solutions
• Tire & Wheel Match Mark • Training and System Documentation
• Stem Detection / Orientation
• Robot Path Correction

6. Robotic Sealing & Coating Additional Advantages
• Multiple Material Applications
• 2K Applications
Applications Include: Our Capabilities Include: • Masking Applications
• Temperature Control
• PVC Anti-Chip – Stone Guard • Process and Feasibility Studies
• Bulk Material Pumps
• Cosmetic Sealer • Simulation – Reach & Cycle time
• Fixed Vision Systems
• Roof Ditch Sealer • Critical Dimension to Body Zero
• EOAT Vision Systems
• Seam Sealer • Mechanical Design
• 7th Axis & Pedestal Robots
• Liquid Applied Sound Deadener (LASD) • Bulk Material Delivery System Design
• Cell Layout
• Controls & Safety Design
• Site Surveys & Laser Alignment
• Build and Detailed Commissioning
• Fluid Calculations
• Complete Installation Services
• Payload & Inertia Calculations
• Safe Distance Calculations
• Thorough System Documentation
• Off-site & On-site Training

7. Custom Machines & Test Systems
Applications Include: Our Capabilities Include:
• Electrical Test Systems • Electrical Engineering
• Precision Cutting • Mechanical Engineering
• Material Dispense and Cutting • 3D Modeling
• Measurement Sensing • Software Development
• Low Frequency Radio Applications • UHF & LF Experience
• Ultra-High Frequency Radio Applications • Extensive Testing Tools
• Specialized Material Handling & Sorting • Integration and Validation Space
• Robotic Manipulation • Supplier Network
• Wireless Devices •Proto-typing
• Wireless Connectivity to Infrastructure •Precision Machining
• Vision Systems •FEA, Simulation

8. Machine Rework / Retrofit / Upgrade / Relocate
Applications Include: Our Capabilities Include:
• Control Systems Upgrades • Electrical Hardware Design
• Servo Upgrades • PLC & HMI Design
• VFD Upgrades • Motion Control
• Robotic Sealing • Mechanical Teardown and Assembly
• Robotic Welding • Dry Ice Blasting & Machine Cleaning
• Roller & Belt Conveyors • Piping and Wiring
• Various Material Handling • Pneumatics & Hydraulics Assembly
• Tire & Wheel Equipment • Painting & Powder Coating
• Printing Presses • Full Debug and On-site Startup
• Paper Converting • Installation Services and Site Management
• Training and New System Documentation

9. Material Handling Solutions
Applications Include: Our Capabilities Include:
• Chain Driven Live Roller (CDLR) • System Layouts
• Line Shaft Conveyors • 3D Design
• Belt Conveyors • Process Studies and Simulation
• Stackers & De stackers • Custom Fixture / Carrier Design
• Palletized Systems • Part Tracking
• Part Orientation Systems • Full Debug and On-site Startup
• Lift Assists • Installation Services and Site Management
• Robotic Applications • Training and System Documentation
• FKI Logistex Integrator

10. Tire & Wheel Assembly Solutions
Applications Include: Our Capabilities Include:
• Complete Roller & Belt Conveyor Systems • Process and Feasibility Studies
• Scheduling, Tracking, and Data Delivery • Simulation & Cycle time
• Wheel Load Process • System Layouts
• Wheel & Tire Vision Systems • Mechanical Design
• Robotic or Manual Stemming operations • Controls & Safety Design Esys Tire & Wheel Assembly
• Tire Load Process • Build and Detailed Commissioning
Solutions can be found in more than
60 tire and wheel assembly plants
• Lift Assists • Complete Installation Services
world wide.
• Material Racks • On-site Support
• Marquee & Operator Interfaces • Extensive Training and Documentation
• TPM Sensor Verification
• Assembly Unload & Delivery
• Product Traceability

11. Our Company Our Capabilities Markets We Serve News
Tire & Wheel Scheduling, Tracking & Data Delivery
Tire & Wheel Tracker System Highlights:
• Specifically designed to handle the data needs of a Tire and Wheel Assembly Process.
• Large installation base and proven reliability
• Single point of control and part information for a distributed system.
• Not a FIFO but rather a "build manifest.“ - localizes sequence issues
• PLC based (PC only as an HMI), this translates into extreme reliability
• Capable of delivering data to equipment in less than 125m seconds
• Not dependent on sequential processes (handles parallel lanes)
• “Buffers" itself from the upper level broadcast system, up to 2-4 hours.
• Allows for a single point to insert or remove assemblies
• Editable "Dictionary" that allows users to enter critical production data

12. Our Company Our Capabilities Markets We Serve News
Dispense & Cut System for 3M Adhesive Wheel Weight Product patent pending
The Esys Dispense and Cut System (DCS) is a machine designed for dispensing and cutting 3M™ weight coil stock for use in balancing of automotive wheels. The 3M™ Wheel Weight
Technology along with Esys’ DCS eliminates the use of lead weights, reduces inventory of individual stick-on or clip-on weights, eradicates waste, and increases correction of imbalance
wheel assemblies by dispensing precise weights on demand.
Highlights: Options: 3M Product Information
• High Torque Stepper Drive provides high level • Mount for boxed weight material
accuracy within +/- 0.5 grams (.0176 oz) • Automatic Unwind System for feeding 250lb spools
• Intuitive remote operator interface • Diverter for Upper/Lower/Scrap Weights
• Capable of dispensing multiple weight profiles • Automated disposal system for liner
• Batch Cut Feature by size and quantity • Pick-To-Light error proofing system
• Product select by linear density
• Quick release blade for easy changing Support:
• Provides center mark in weights
• Professional Service / Maintenance Manuals
• Material detection sensors for end
• On-Site Training
of material and splice detection
• 24 Hour Emergency Support Hotline – Esys “Hot-Seat”
• Easily integrates with balancer equipment
Support Staff
• Built in safety features
• 1-Year Standard Warranty
Photos and logos used with permission from 3M
Contact Us File Exchange Esys Login

13. Tire Pressure Monitoring System (TPMS) Solutions
Applications Include: Our Capabilities Include:
• Data Marriage Systems • Operates with nearly all sensors on the market
• Verification Systems • Siemens • Schrader
• Handheld Tools • TRW • Hyundai
• Autonet
• Lear
• Pacific
• Redundant RF receivers in every antenna.
• Broadband Technology to handle multiple frequencies
• Digital receiver "tunes" itself
• Advanced software algorithms to distinguish bad signals
• Variable LF module with power output readout
• Designed to integrate into existing PLC / PC control systems
• A monitored cam break-away stand - vertical or horizontal mount

14. Esys MES Software Solutions
With Manufacturing Execution Systems (MES) options starting at under $30,000.00, Esys offers the least expensive MES system on the market.
On the plant floor, operators and tooling have the biggest impact on cost and quality. Esys provides the first and only manufacturing execution (MES)
system to emphasize on the operator and tooling.
Esys MES solutions are built by manufacturing integration engineers, not IT software people. Our engineers spend more time on concrete than carpet,
creating real world solutions for manufacturing excellence.
Applications Include: Our Capabilities Include:
MES Benefits:
• Genealogy & Traceability • Interfaces to ERP/MRP/WMS
• Increased Productivity
• Quality Systems, SPC • Interfaces to PLC’s, Tools & Testers
• Reduce waste
• Paperless Work Orders / Travelers • Intuitive Operator Interfaces
• Increase quality
• Electronic Work Instructions • On-site & Remote Support
• Reduced inventory
• Pick to light, Put to light • Inexpensive Hardware Solutions
• Better metric information
• Material Visibility • Training and System Documentation

15. Esys MES Software Solutions
Genealogy & Traceability
Less than accurate traceability and genealogy data can cause untold lost profits.
Our manufacturing knowledge allows us to collect data with greater integrity than our
competitors, with concise reporting customized to your specific needs.
Applications Include:
• Genealogy & Traceability
• Quality Systems, SPC
• Paperless Work Orders / Travelers
• Electronic Work Instructions
• Pick to light, Put to light
• Material Visibility

16. Esys MES Software Solutions
Quality Systems, SPC
• Enforces product tolerance checks using control charts
• Early detection of variances that would adversely affect quality
• Correct defects before subsequent processes begin
• Some of our system benefits include:
• X-R quality control charts for SPC
• Parts / Processes easily added, modified using color coded tree views
• Data collection accomplished via machine interface or operator entry
Applications Include:
• Genealogy & Traceability
• Quality Systems, SPC
• Paperless Work Orders / Travelers
• Electronic Work Instructions
• Pick to light, Put to light
• Material Visibility

17. Esys MES Software Solutions
Electronic Work Instructions
Electronic work instructions lower training cost and provide consistent
quality.
• Designed for high option content workstations
• Allow operators to move seamlessly from workstation to workstation
• Easily configurable for process changes,
• Capable of displaying graphical images
Applications Include:
• Genealogy & Traceability
• Quality Systems, SPC
• Paperless Work Orders / Travelers
• Electronic Work Instructions
• Pick to light, Put to light
• Material Visibility

18. Esys MES Software Solutions
Pick to Light, Put to Light
A standard for some of the world’s largest
Right Part
manufacturers, Esys is one of the only providers of
• Easily identifies part to pick
non-contact “pick to light” systems. Our fully
• Notifies pass/fail operations
implemented systems are typically 25% less expensive
• Ensures correct tasks are performed
than our competition’s.
Right Place
• Flexible station locations
• Mobile job stations available
Applications Include:
• Individual indicators per part/station
• Genealogy & Traceability
Right Time
• Quality Systems, SPC
• Operation downloads in real-time
• Paperless Work Orders / Travelers
• Real-time result logging
• Electronic Work Instructions
• Informs operator in real-time
• Pick to light, Put to light
• Material Visibility

19. [ ISO 9001:2000 Certified
[ 99.2% Overall Customer Satisfaction
[ Data compiled from over 60 individuals
80%
70%
60%
Below Expectations 50%
Meets Expectations
Exceeds Expectations40%
30%
20%
10%
0%

20. OUR CORE BELIEF
All efforts are to be focused on meeting the needs of the customer.
We will provide our customers with a level of service, support,
and competency that is the benchmark of the industry.