Federal-Mogul Corporation Business Report FY2010

Business Highlights

Financial Overview

(in million dollars)
  FY2010 FY2009 Rate of
change (%)
Sales 6,219 5,330 16.7 -
Net Income 161 (45) - -
Powertrain Energy (PTE)
Sales 1,860 1,413 31.6 1)
Powertrain Sealing and Bearings (PTSB)
Sales 1,096 818 34.0 2)
Vehicle Safety and Protection (VSP)
Sales 936 773 21.1 3)

Powertrain Energy (PTE)
-Sales volumes increased by $470 million due to OE production volume increases and market share gains in all regions. The acquisition of the Daros Group increased sales volume by $16 million. PTE generates approximately 80% of its revenue outside the United States and the resulting currency movements decreased sales by $30 million. Continued customer pricing pressure reduced sales by $9 million.

Powertrain Sealing and Bearings (PTSB)
-Sales volumes increased by $301 million due to OE production volume increases and market share gains in all regions. Approximately 65% of PTSB's revenues are generated outside the United States and the resulting foreign currency movements decreased sales by $19 million. Continued customer pricing pressure reduced sales by $4 million.

Vehicle Safety and Protection (VSP)
-Sales volumes rose by $186 million due to increased OE production and market share gains in all regions. Approximately 70% of VSP sales are generated outside the United States and the resulting currency movements decreased sales by $11 million. Continued customer pricing pressure reduced sales by $12 million.


-The Company provides a wide range of power-cylinder, sealing, bearing and heat insulation components for the award-winning Ward's engines. The engines that feature its products are: Audi A4 2.0L TFSI Turbocharged DOHC I-4; Audi S4 3.0L TFSI Supercharged DOHC V-6; BMW 335d 3.0L DOHC I-6 Turbodiesel; Ford Fusion Hybrid 2.5L DOHC I-4 Hybrid; Chevrolet Equinox 2.4L Ecotec DOHC I-4; Hyundai Genesis 4.6L Tau DOHC V-8; Subaru Legacy 2.5 GT 2.5L Turbocharged DOHC H-4; Toyota Prius 1.8L DOHC I-4 Hybrid; Volkswagen Jetta Sport Wagen TDI 2.0L SOHC I-4 Turbodiesel (From a press release on January 13, 2010)

-Ford announced that it is adding 13 new companies to its Aligned Business Framework (ABF), bringing the total to 90 members. The new ABF suppliers are: the Company; Akebono; Automotive Lighting; Benteler; Brembo; Gentex; GKN; Hayes Lemmerz; Key Safety Systems; Michelin; Ronal GmbH; Samvardhana Motherson Reflectec; Takata. Ford created ABF in 2005 to strengthen its collaboration with key suppliers. (From a Ford press release on April 23, 2010)


-The Company has received the 2009 Supplier of the Year Award from General Motors, in recognition of its performance in engine piston products. The Company supplies aluminum pistons, rings and connecting rods to GM for both passenger cars and light trucks. This is the third consecutive year the Company has received the GM award. (From a press release on March 12, 2010)

-The Company was granted the Automotive News PACE awards for three of its innovations, including its DuraBowl(R) piston reinforcement process, its High Precision Electro-Erosion Machining (HPEEM) manufacturing process and the Company's Bayonet Connection System for profile wiper blades in the Product-Europe category. The system is featured on more than 20 vehicle platforms. (From a press release on April 13, 2010)

-The Company was honored by Chrysler Group LLC for its performance in providing powertrain components and enabling the successful launch of the 2011 Jeep Grand Cherokee. The Federal-Mogul powertrain products recognized are produced at its U.S facilities in Athens, Alabama; Blacksburg, Virginia; Lake City, Minnesota; and Waupun, Wisconsin. (From a press release on October 20, 2010)


R&D Expenditure

(in million dollars)
  FY2010 FY2009 FY2008
Overall 156 140 173

R&D Facilities

(As of Dec. 31, 2010)

  U.S. and Canada Europe Rest of World
Technical centers 8 7 2

US: Plymouth, Michigan; Skokie, Illinois; Ann Arbor, Michigan; and Exton, Pennsylvania.
Internationally: Burscheid, Germany; Nuremberg, Germany; Wiesbaden, Germany; Bad Camberg, Germany; Chapel, United Kingdom; Crepy, France; Shanghai, China; Bangalore, India; Yokohama, Japan.

-The Company has opened its Asia Pacific Headquarters and Technical Center in Shanghai, China. The facility houses approximately 300 employees including engineering, sales and administrative personnel. The center, the Company's 18th, offers technology development and product engineering and has capabilities to conduct tests on powertrains and other vehicle components. The Company, in addition to the newly-established Asia Pacific Headquarters and Technical Center, has seven plants in China. (From a press release on June 25, 2010)

Product Development

Crankshaft oil seal
-The Company has developed a new crankshaft oil seal called MicroTorq(TM) incorporating 'double-hinge' lip design. This new seal reduces friction by up to 70 percent versus conventional lip-type seals. (From a press release on March 17, 2010)

Shielding sleeve
-The Company has developed new shielding sleeve, which helps protect vehicle electrical/electronics architecture against electromagnetic interference (EMI). The shielding product features a braided, tinned, copper wire combined with a hybrid yarn technology. Its EMI shielding products are developed at the Company's technical centers in Exton, Pennsylvania, USA and Crepy-en-Valois, France. (From a press release on March 18, 2010)

Bearing overlay
-The Company developed IROX(TM) bearing overlay. The IROX bearing overlay can help increase the life of crankshafts and bearing shells by more than five times in direct-injected engines and engines with stop-start systems. (From a press release on March 22, 2010)

Polyethylene Terephthalate yarn
-The Company has developed Polyethylene Terephthalate (PET) yarn to meet the halogen-free flame-retardant regulations. The Company is now developing commercialization plans to enable volume manufacture of this new fabric. The new PET yarn will be used in interior trim and wiring harness insulation used in vehicles among other applications. (From a press release on May 24, 2010)

EcoTough(R)-coated piston
-The Company has developed a new EcoTough(R)-coated piston for gasoline engines. This coating technology is comprised of solid lubricants, including graphite, molybdenum disulfide (MoS2) and carbon fiber. EcoTough(R)-coated piston reduces fuel consumption up to 0.8 percent, as well as reduced CO2 emissions, compared to conventional coated pistons. The pistons are currently in production, having been selected by a major European manufacturer. (From a press release on July 20, 2010)

Two-piece oil ring
-The Company announced the availability of its LKZ(R) two-piece oil ring for direct-injection gasoline engines. LKZ(R) has already been used in diesel engines. The oil control ring reduces oil consumption by up to 50 percent and friction by up to 15 percent, compared to the conventional two-piece oil rings. (From a press release on August 19, 2010)

Monosteel(R) piston
-The Company announced that it has developed the next generation of the Monosteel(R) piston, called Magnum Monosteel(TM). The new design reduces piston mass by up to seven percent, and offers improved fuel economy and reduced emissions for heavy-duty diesel vehicles. The Company developed the Magnum piston at its Powertrain Energy technical center in Plymouth, Michigan, U.S.A. (From a press release on October 14, 2010)

High Temperature Alloy (HTA) gaskets
-The Company announced it has developed a new portfolio of High Temperature Alloy (HTA) gaskets. The HTA technology, already used for heavy-duty diesel engines, is now applicable to light-duty diesel and gasoline engines. Federal-Mogul's HTA gaskets are produced in Athens, Alabama, U.S.; Skokie, Illinois, U.S.; and Herdorf, Germany. (From a press release on November 17, 2010)

Investment Activities

Capital Expenditures

(in million dollars)
  FY2010 FY2009 FY2008
Powertrain Energy 119 76 140
Powertrain Sealing and Bearings 58 44 70
Vehicle Safety and Protection 51 38 71
Global Aftermarket
5 2 4
Corporate 18 16 35
Total 251 176 320