Latest Newsletter on Leoni's cord set and harness business

1. insider
Electrical Appliances · 2 / 2011
Dear Insiders,
Topics This issue deals with two major accomplishments within LEONI EA since our last news-
letter:
■■ News from plants
I. LEONI Cables Xiamen – Firstly, our operations in Xiamen, China moved into new premises. This enables us to
new location implement a totally new production flow. We now dispose of much more production
II.LEONI Slovakia – rotary surface, which makes it possible to set up new equipment, enhance processes, and
moulding system increase output.
■■ Textile and steam tube cables
■■ New products Secondly, in Slovakia we recently added a new, fully automated production line to our
already advanced machinery. This latest line however, excels because we made use of
the most innovative moulding technology available: a rotary injection press. This will
not only ensure higher flexibility in shapes, but will enable us to surpass the output
speed of any other technology available for the production of power cords.
Even tough such achievements represent a considerable challenge for our organisa-
tion, they symbolise unmistakably the path we are pursuing:
“Sustainable growth through innovation of technologies and products!”
Published by
LEONI Cable Assemblies GmbH
Roth
Best regards,
Phone +49 (0)9171-804-2640
Fax +49 (0)9171-804-2190
Editorial staff
Claudia Schertel
Christoph Wolf Luc Wagemans
Sabine Kerschbaum
Senior Vice President Sales Director
LEONI insider is a publication for Business Group
customers of the Business Group Electrical Appliance Assemblies
Electrical Appliance Assemblies.
Subject to technical changes.
© LEONI Cable Assemblies GmbH,
Marketing

2. News from plants
I. LEONI Cables Xiamen – new location
In 1991, when LEONI decided to set up a port guarantees first rate export perfor-
second plant in China for the production mance, not only to Southeast Asia but
of cordsets and wiring for the appliance also to Europe and the Americas.
industry, Xiamen turned out to be the
favoured location to serve customers in In addition to the transport connection,
southern China. Approx. 970 km away the new location offered LEONI the
from LEONI Cable Changzhou, the plant’s possibility to specify a completely new,
successful performance underscores this state-of-the-art factory layout that
decision. considers the material flow in the
different production steps and allows
In line with the growth of the appli- further expansion.
ance industry in China in general, LEONI
suceeded in obtaining new customers After exact planning of the relocation,
and in enlarging its existing business LEONI finally started operations in the
in both the cordset and internal wiring new building on July 26th, 2011.
segments. It isn’t surprising that 20 years
after its foundation, the plant bursted
at the seams and had to move to new
premises.
With LEONI being convinced of the
logistical advantages offered by Xiamen,
there was no question that the new plant
would be located in the same city. The
province of Fujian enables LEONI to offer
excellent logistical support to its custom-
Changzhou
ers in southern China. A new motorway
leads to the city Shenzhen in the southern
Xiamen
province of Guangdong. Its international Shenzhen
Hong Kong
Facts
Production area 12,000 m²
Office area 900 m²
Employees more than 500
New address
No. 28, Pingcheng Central Road, Haicang, Xiamen, China.
2 LEONI insider

3. We would like to invite you to join us for a plant tour:
LCX’s main products are power cords and a large LCX’s harnesses workshop consists of one circinate
variety of cable assemblies and harnesses. production line and various independent work-
The plant is equipped with 16 conventional produc- stations for forklift harnesses, washing machine
tion lines and two automatic production lines harnesses, refrigerator harnesses, etc.
for power cords. The lines mentioned first were For the production of PVC cables according to CCC,
designed by LCX and can be adapted to produce VDE, UL, AUST, PSE and EK-MARK, LCX is equipped
a huge range of local and international plugs and with five extrusion lines.
connectors. The two automatic production lines LEONI Xiamen is currently certified according to
were designed in Europe, one for the production of VDE, UL, PSE, ENEC, ESTI, KEMA, KEMA-BS, SPRING,
Euro class 2 connector cords and the other for high IMQ, Australia, IRAM, KC-MARK, UCIEE, BSMI
runner CCC 2-core power cords. and CCC.
Third Floor:
– Harness area
– Corridor
– Office area
– Meeting room
Second Floor:
– Extrusion line
– Shaver cord lines
– Raw materials warehouse
– Laboratory
First Floor:
Power cord production
– Automatic production lines
– Manual production line
– Extrusion line
– Warehouse for finished goods
Outdoor area:
– Front view of the building
– Entrance area
Main focus of the laboratory 3. Special tests in accordance with customer’s
The laboratory provides testing equipment for: specification: flexible for low temperature test,
1. Tests on cables: flexing test, geometry, mechani- seismic resistance test, breakdown test, tension
cal properties, electric tests, flame tests, and test and rotation test.
aging tests according to UL, VDE, CCC and other 4. PVC compound test: melt flow rate (MFR), den-
standards (PVC and Rubber). sity, migration, etc.
2. Tests on power supply cord: cord anchorage test, 5. Hazardous substances test: RoHS (Plumbum
dimensions, mechanical and electrical tests. Pb, quicksilver Hg, cadmium Cd, chrome Cr and
total bromine Br).
LEONI insider 3

4. II. LEONI Slovakia – rotary moulding system
Due to a huge wave of production reloca-
tion to Southeast Asia, R & D spending
on further automation steps in power
cord manufacturing was reduced over
the past few years among our machine
supplier base. However, we have now
spotted one real process innovation in
a new technology: the rotary mould-
ing press. The idea is derived from the
beverage industry, more specifically from
injection moulding of plastic bottles, and
has now been adapted to our industry
in cooperation with one of our machine
suppliers.
How does it work?
The rotary table is a moulding machine What are the advantages?
with a rotating set-up that performs ■■ Each cavity can be set in a different
one-piece flow moulding. The single way (quality).
moulding cavities mould one product. ■■ Machine can use different types of cav-
12 injection units, one for each cavity, are ities on the same rotary table making it
fixed on the rotary table. possible to mould 2 sides (connectors)
at the same time (flexibility).
By connecting the machine to a plug ■■ Speed of assembly line can be adapted
assembly crimping line with a robot load- easily (output).
ing system we achieve a fully automatic ■■ Fully linked in each process (quality).
power cord machine.
This example documents LEONI’s
expectations with respect to its own
performance: Process safety across the
complete value chain is one of our prom-
ises to our customers – and we continu-
ously endeavour to improve.
4 LEONI insider

5. Textile and steam tube cables
1
1
1
2
2 2
1 Textile cable 1 Mono tube 1 Steamer hose
2 Steamer iron 2 Ironing system 2 Garment steamer
The acquisition of LEONI Furas some Mono tube – H05BB – for H05GG-F Steamer hose – 17 x 24 mm Silicone
years ago enlarged our product cable and EPDM tube or PVC tube
portfolio to include textile and steam The mono tube is mainly used for ironing The main application for steamer hose
tube. With China being the main mar- systems on the European market and is is for garment steamers on the Chinese
ket for textile and steam tube cables, characterised by higher requirements. market. In contrast to many local manu-
LEONI, as a technology leader and With each appliance manufacturer hav- facturers using PVC tubes, LEONI uses
for some technologies even exclusive ing its own requirements, the products silicone tubes. With silicone tubes, LEONI
manufacturer of these solutions, pro- need to pass extensive tests such as has a unique feature in the market.
duces these cable types at its Chinese flexing tests, air pressure tests or high
facilities. voltage tests. The advantages of LEONI silicone
tubes are:
The market requires three main types: A recent market survey published by ■■ halogen free
■■ Textile cable (H03RT-H cable) GfK, a German market research institute, ■■ odourless
■■ Mono tube (H05BB-F or H05GG-F cable in August 2011 shows a clear trend in ■■ high temperature resistant
and EPDM tube) consumer behaviour in Europe. Steam
■■ Steamer hose (silicone or PVC tube) tube irons are among the small appli-
ance products that show a double-digit
Textile cable – H03RT – H cable growth rate in Eastern Europe. In Europe We are proud that the world’s leading
For the mass market of steamer irons, in general, it is not only the quantity of brands order their textile cables, textile
textile cable is used on a worldwide scale products sold that is increasing, consum- power cords, steam tubes and steamer
with the only exception being the North ers are also clearly opting for high quality hoses from us!
American and Japanese market. products. This trend encourages the
appliance industry to invest in new devel-
opments, e.g. low-energy use, reduction
of waiting times until the temperature is
reached, easier ironing, ... With many key
players using LEONI mono tube for their
ironing systems, it became one of the
most important innovative products at
LEONI Cable Changzhou, China.
LEONI insider 5

6. New products
Plug 3170
Plug 3170 broadens our portfolio as the
anti-tracking plug for Japan. In addition Plug 3170 LAS-16
to the 3 versions for 2-pole power cords,
plug 3170 now makes the first 3-pole ver-
sion deliverable. LAS-16
Its additional anti-tracking capacity is This 2.5 A connector is available in a hal- consumer electronics to supply TVs and
achieved by partial insulation of the ogen-free version and thus enhances our DVD players with power. The CW4771
poles. The plug is made at LEONI’s Xia- portfolio of halogen-free products. The version continues to be available for PVC
men plant. LAS-16 connector is used especially for cables.
LEONI’s portfolio of halogen-free products now comprises the following plugs and connectors:
Plugs & Connectors
Country or Approved by Plug type Connector Approval mark Cable type Manufacturing plant
region type
Europe KEMA CW3061 KEMA H03Z1Z1-F 3G0,75 LS
H05Z1Z1-F 3G0,75
H05Z1Z1-F 3G1
CW4014 ENEC H03Z1Z1H2-F 2X0,5 LS/LCC/LCX
H03Z1Z1H2-F 2X0,75
H05Z1Z1H2-F 2X0,75
CW4771 ENEC H03Z1Z1H2-F 2X0,5 LS
H03Z1Z1H2-F 2X0,75
H05Z1Z1H2-F 2X0,75
LAS 16 ENEC H03Z1Z1H2-F 2x0.5 LCC/LCX
H03Z1Z1H2-F 2x0.75
H05Z1Z1H2-F 2x0.75
705 ENEC H03Z1Z1-F 3G0,75 LCC/LCX
H05Z1Z1-F 3G0,75
730 ENEC H05Z1Z1-F 3x0.75 LS/LCC/LCX
H05Z1Z1-F 3x1.0
H05Z1Z1-F 3x1.5
286 KEMA H03Z1Z1-F 3X0,75 LS/LCC/LCX
H03Z1Z1H2-F 3X0,75
H05Z1Z1H2-F 2X0,75
H05Z1Z1H2-F 2X1
H05Z1Z1-F 2X0,75
H05Z1Z1-F 2X1
300 KEMA H03Z1Z1-F 3G0,50 LS/LCC/LCX
H03Z1Z1-F 3G0,75
H05Z1Z1-F 3G0,75
H05Z1Z1-F 3G1
H05Z1Z1-F 3G1,5
365 KEMA H03Z1Z1-F 3G0,75 LS/LCC/LCX
H05Z1Z1-F 3G0,75
H05Z1Z1-F 3G1
H05Z1Z1-F 3G1,5
6 LEONI insider

7. Plugs & Connectors
Country or Approved by Plug type Connector Approval mark Cable type Manufacturing plant
region type
Switzerland ESTI 205 S+ H05Z1Z1-F 2x0,75 LS/LCC/LCX
H05Z1Z1-F 2x1
H05Z1Z1H2-F 2x0,75
H05Z1Z1H2-F 2x1
Italy IMQ 206 IMQ H03Z1Z1H2-F 2X0,75 LS/LCC/LCX
H05Z1Z1H2-F 2X0,75
H05Z1Z1H2-F 2X1
H05Z1Z1-F 2X0,75
H05Z1Z1-F 2X1
UK KEMA CW3201 KEMA UK H03Z1Z1H2-F 2X0,75 LS/LCC/LCX
H05Z1Z1H2-F 2X0,75
H05Z1Z1H2-F 2X1
H03Z1Z1-F 2X0,75
H05Z1Z1-F 2X0,75
H05Z1Z1-F 2X1
H05Z1Z1-F 2X1,5
H03Z1Z1-F 3G0,75
H05Z1Z1-F 3G0,75
H05Z1Z1-F 3G1
H05Z1Z1-F 3G1,5
UK KEMA CW3202 KEMA UK H03Z1Z1H2-F 2x0,75 LS/LCC/LCX
H05Z1Z1H2-F 2x0,75
H05Z1Z1H2-F 2x1
H03Z1Z1-F 2x0,75
H05Z1Z1-F 2x0,75
H05Z1Z1-F 2x1,0
H05Z1Z1-F 2x1,5
Singapore KEMA CW3201 KEMA UK H03Z1Z1H2-F 2X0,75 LS/LCC/LCX
H05Z1Z1H2-F 2X0,75
H05Z1Z1H2-F 2X1
H03Z1Z1-F 2X0,75
H05Z1Z1-F 2X0,75
H05Z1Z1-F 2X1
H05Z1Z1-F 2X1,5
H03Z1Z1-F 3G0,75
H05Z1Z1-F 3G0,75
H05Z1Z1-F 3G1
H05Z1Z1-F 3G1,5
Singapore KEMA CW3202 KEMA UK H03Z1Z1H2-F 2x0,75 LS/LCC/LCX
H05Z1Z1H2-F 2x0,75
H05Z1Z1H2-F 2x1
H03Z1Z1-F 2x0,75
H05Z1Z1-F 2x0,75
H05Z1Z1-F 2x1,0
H05Z1Z1-F 2x1,5
LEONI insider 7

8. Cable types
Country or region Approved by Approval Cable type Manufacturing
mark plant
Europe VDE HAR VDE H03Z1Z1H2-F 2 x 0,5 LS
(+ HAR Recognizing countries) H03Z1Z1H2-F 2 x 0,75
H05Z1Z1H2-F 2 x 0,75
H05Z1Z1H2-F 2 x 1
H03Z1Z1-F 2 x 0,5
H03Z1Z1-F 2 x 0,75
H05Z1Z1-F 2 x 0,75
H05Z1Z1-F 2 x 1
H05Z1Z1-F 2 x 1,5
H03Z1Z1-F 3G0,75
H05Z1Z1-F 3G 0,75
H05Z1Z1-F 3G1
H05Z1Z1-F 3G1,5
VDE H03Z1Z1H2-F 2 x 0,5 LCC / LCX
H03Z1Z1H2-F 2 x 0,75
H05Z1Z1H2-F 2 x 0,75
H05Z1Z1H2-F 2 x 1
H03Z1Z1-F 2 x 0,5
H03Z1Z1-F 2 x 0,75
H05Z1Z1-F 2 x 0,75
H05Z1Z1-F 2 x 1
H05Z1Z1-F 2 x 1,5
H03Z1Z1-F 3G0,50
H03Z1Z1-F 3G0,75
H05Z1Z1-F 3G0,75
H05Z1Z1-F 3G1
H05Z1Z1-F 3G1,5
LEONI insider 8