CALTHERM CORPORATION

1. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI CALTHERM CORPORATION David Langenderfer Fall 2004 Coop Session Department of Mechanical Engineering, IUPUI Intern/Coop Presentations: March 24, 2005

2. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Introduction Co-op at Caltherm Corporation in Fall 2003, Summer 2004 and Fall 2004 Engineering Lab Associate – Fall 2003 Manufacturing Engineer – Summer 2004 Lab Engineer – Fall 2004 BSME – Senior

3. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Description of Caltherm Manufacturing Facility in Columbus, IN opened in 1979 Supply diesel engine thermostats 60,000 sq. ft. over 150 employees Acquired Vernay Labs in 1987 Acquired Eaton thermostats in 2003

4. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI

5. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Description of Duties Design various close and stamp tooling Design multiple leak test fixtures Update documentation Kan Ban implementation Spring vs. Dead weight rack comparison Upgraded life cycle testing procedure Designed and implemented new high pressure test stand

6. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Tooling Designs Designed prototype close tooling for balanced thermostat for CAT Designed new tooling for the V-Stat line Designed prototype close tooling for Pressure Relief Valve for Racor. Adjustable die for squeeze push element Plate for life cycle testing Adjustable plate for sensor

7. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Various Tooling

8. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Leak Test Fixture Modified existing design to accommodate new seal Designed using Solid Edge, created and assembled features to determine the appropriate fit Sent to tool room to be made Created work instruction on how to use the leak test fixture

9. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Leak Test Fixtures

10. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Update Documentation Create APQP documentation such as: PFMEA, control plans, flow charts and work instructions Created flow charts for multiple low flow cells Checked and modified documentation on CAT side bump

11. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Kan Ban Implementation Determine the 25 most common wax mixes Create the Kan Ban board and tags Install the Kan Ban board Explain how to use the Kan Ban to the involved employees

12. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Spring vs. Dead Weight Create a test procedure for testing the difference between a spring and dead weight rack Test the two racks with multiple elements and various temperatures Report my findings

13. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Life Cycle Test Procedure Increase accuracy Increase repeatability Easier replacement Ability to run 24 hours Refill system

14. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI High Pressure Stand Pressure drop Measure flow Look professional Safety Quick part changes

15. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Other Tasks Create safety features Create fluid recovery system Modify wiper seal line Design parts rack Design coolant mister Modify Harley-Davidson tooling

16. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI

17. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI

18. 03-24-05 David Langenderfer, Department of Mechanical Engineering, IUPUI Any questions?