Automotive Engineering International
Improving a seat's look and feel
(January 2009)

• New features and functions can make seats more attractive, but the foams and coverings continue to play a huge role in a seat's overall appeal. These material technologies continue to evolve, helping lower weight and improve the look and feel of an interior. Rear seats don't get the same level of marketing attention as front seats, but they are also changing rapidly. The emergence of foams that are strong and supportive yet still soft make it possible to eliminate metal frames and trim weight. "With structural foam, we replaced a rear seat system that used steel wire frames," said Don Bernhardt, Vice President, Product Engineering for Lear's Seating Systems Division. That saved about 7 kg (15.4 lb), he noted. Foams that aren't based on petroleum products are gaining acceptance helping product designers meet environmental goals by using materials that are more readily recycled. Though usage is still small, sustainability is an important factor for many automakers. While foams evolve, seat coverings are also changing. Leather has moved from luxury vehicles into the mainstream, now accounting for 35-40% of seating sales in the U.S. As usage has grown, suppliers have come up with new ways to let designers set their seats apart from the crowds.

Ford Press Release
Ford, Lear Earn Accolades For Innovative Use Of Soy Foam in Seat Cushions
(December 2008)

• Ford's innovative use of this renewable bio-material has earned several prestigious awards, including winning the "Environmental" category at the recent 2008 Innovation Awards competition sponsored by the Society of Plastic Engineers (SPE) Automotive Division. The honor is shared with supplier Lear Corp. Ford dominated the recent event by winning four of eight categories as well as the top vehicle award for the most innovative uses of plastics on one vehicle, the 2009 Ford Flex.
  

 The Wall Street Journal
Lear's CEO makes big bet on company
(November 12, 2008)

• The chairman and chief executive of one parts supplier has decided it is a good time to invest. Lear Corp.'s Robert Rossiter bought 225,000 Lear shares on Friday for about $400,000, and he said he would buy more shares. "This stock is so undervalued, it's unbelievable," he said. Lear has been clobbered by the uncertainty surrounding Detroit and the credit crisis. Lawmakers are considering an assistance package for the American auto industry and Mr. Rossiter said help is needed. But that is not what he is betting on. "I'm betting on my own company." He said the company's business fundamentals haven't changed since 2007, when Carl Icahn took a significant stake in the company and launched a $2.85 billion takeover bid, offering $37.25 a share to take Lear private. Shareholders voted the offer down." Shareholders rejected that deal, holding out for $60 [a share]," Mr. Rossiter said. "Nothing's changed." Four days before Mr. Rossiter's purchase, Mr. Icahn and his affiliates reduced their Lear stake to 4.95% from 16%, selling 8.5 million shares to book capital losses for tax purposes, according to a regulatory filing. Mr. Icahn, often a vocal critic of management at companies he invests in, struck an affable tone in a note to Lear's board of trustees on the day of his stock sale, saying he had "great respect" for the company's "extremely competent executives."
  

Ward's Auto
Lear tying EVs to power grid with new charging unit
(October 2008)

• Lear Corp. is forging ahead with onboard charging systems tfor plug-in hybrids and electrich vehicles hat connect these new cars and trucks to national power grids. Highlighting the company's display of wiring and power-distribution products, such as smart junction boxes, audio amplifiers and body electronics, officials on hand at the Convergence Transportation Electronics Conference say the new charging units aim to broaden Lear's electrical portfolio and position it for the pending growth of alternative-power solutions. Lear says the chargers work by enhancing the efficiency of a wall socket's alternating current and then converting it to a direct current of electricity, after which it is boosted up to about 340 volts before entering the battery. Compared with a conventional hybrid-electric vehicle, the PHEV/EV system only adds the battery charging unit and its connection to the battery's power controller, as well as the external plug-in socket. While standard, overnight trickle charging likely will be used most often, the technology is robust enough to handle the higher amperages of quick charging (one or two hours) via a DC-to-DC power source. Lear is working on several new technologies that will allow energy utilities to recognize certain users when they charge up remotely and bill their home accounts accordingly.

Crain's Detroit Business
2008 Crain's 40 Under 40 - Scott French
(October 2008)

• For the past 18 years, Crain's Detroit Business has honored the best and brightest in Southeast Michigan who have made their marks in business before age 40. More than 400 people were nominated for this year's 40 Under 40. Crain's evaluated candidates based on personal achievement and community impact. Scott French, vice president of global metals for Lear Corp., was an honoree this year. Scott was selected based on his success in leading the financial turnaround of Lear's money-losing European interiors operations in 2004-2005, improving product quality and earning $175 million in new business. In his current role as vice president of Lear Corp.'s $934 million global metals business, Scott French has to travel the world to find the lowest-cost metals available. French's track record ultimately led him to be one of the youngest of Lear 's top leaders in the company's automotive seat business when he was promoted to his current position last February.

Urethanes Technology International
Light weight, "green foam", high comfort key factors in auto seating
(Aug/Sept 2008)

• Seat makers have to reduce weight, while keeping comfort at the very high levels that car makers, particularly the premium-brand German OEMs, expect. The urgency to reduce weight has stepped up a beat now, driven both from this CO2 regulation proposed for 2012 in Europe, and as well by fuel efficiency. Added impetus here comes from soaring fuel prices, which are hitting consumers, not only in Europe but in North America as well. So there is a strong drive towards lighter weight parts, and since seating systems represent almost 40 percent of the weight of a vehicle's main interior components. For automotive seat maker Lear Corp., based in Southfield, Michigan, "Environment is a big thing, so anything that improves the renewability or recyclability or safety of the product is of great importance to our customer," commented Ash Galbreath, Lear's director of advanced materials and comfort engineering. One approach Lear has taken here is the introduction of extremely lightweight expanded polypropylene (EPP) foams combined with PU foam, in seating.  As well as its enthusiasm for alternatives to foam, Lear places considerable emphasis on its in-house soya polyols: Lear has provided soya-based foam for the Ford Mustang seats since last summer and is also converting other vehicles. Lear also has joint projects with suppliers, so some of those are staged to change soon, Galbreath added. With TDI foams, he said, soya polyols can currently be used at about 5 percent in seat pads, and with MDI, Lear can go up to 28 percent.

Automotive Design and Production
Lear Corp.'s Integrated Power Module designed to make hybrids more space and energy-efficient
(August 2008)

• Lear's Integrated Power Module (IPM)combines a 300-V distribution box, 120-V AC power outlet inverter, 12-V and 42-V DC-DC converter, and traction power inverter module in a single unit. The design eliminates three high-voltage connectors, three high-voltage harnesses, up to four cold plates, and up to five enclosures which streamlines the manufacturing process, requires fewer external interfaces such as connectors, cooling hoses, retainers, and harnesses and eliminates a minimum of 11 processes. Lear estimates its IPM has a mass savings of 15 lb., a cost savings of at least 20% when compared to more conventional designs, improved safety through the use of redundant primary components and smart electronics, greater electrical efficiency, and the ability to be packaged in a less obtrusive space.

Automotive News
Seat strategy: Lear aims to make more profits by producing more parts
(July 2008)

• Lear Corp. is looking to boost revenue by manufacturing more of the components that go into its seats. In the past, the company has produced few seat coverings, which represent about 15 percent of a seat's cost. Lear also has outsourced the vast majority of seat structures to suppliers. But that's changing, says Lou Salvatore, senior vice president in charge of seats at Lear. Last month Lear bought a 75 percent stake in the fabric business of New Trend Group Co. Ltd. of China. Lear launched a leather line for seats late last year. And Lear is bringing frame making back in-house in a big way, Salvatore, 52, told Automotive News. Lear is continuing to diversify its product offerings and its traditional customer base and regional sales mix with more business coming from Asian customers and regions. For example, Lear has opened a foam plant in Wuhu, China, and a seat trim facility in Hai Phong, Vietnam. Salvatore said Lear seeks acquisitions that would add components or open more markets to the company, but nothing is imminent. The acquisition of New Trends' automotive fabric business is aimed at China, at least initially, he said. The Shanghai-area company posted sales of about $30 million last year. Lear predicts its seat sales in China will reach $1 billion this year. Owning a leather company and a fabric maker lets Lear design into its seats fancier stitching and designs, said Don Bernhardt, vice president of engineering for Lear's North American seating unit. Lear launched its Aventino collection of premium automotive leather last autumn in Detroit. Frames also can be a game-changer, Salvatore said. Lear makes an ultralight frame for the seats it supplies on the Mercedes-Benz SLK roadster. The stylish, exposed steel back saves weight, a major selling point to carmakers. 

Ward's Auto
Designers push to make vehicle interiors more eco-friendly
(June 2008)

• Terms such as bamboo, seaweed cellulose yarn and bio-based polyester are becoming more mainstream in automotive design lingo today, in an industry effort to make vehicle interiors more eco-friendly.  The use of these and other natural materials, such as corn, soybeans, rice hulls and coconut fibers, along with recycling materials, is enabling interior designers to lessen a vehicle's impact on the environment, a panel of experts says at the Ward's Auto Interiors Show. Lear Corp. also has been replacing its petroleum-based foam in vehicle seat cushions, seatbacks, arm-and-head rests with soy-based polyurethane foam.  With the market struggling, using environmentally friendly materials is one way to keep consumers interested.

Detroit Free Press
Lear's electronics side to quadruple
(May 2008)

• Lear plans to grow its electronics business, which makes products including wire harnesses and remote keyless entry systems, from $3.1 billion last year to $12 billion to $15 billion during the next three to five years, Lear CEO Bob Rossiter said in an interview Thursday after the company's annual shareholder meeting.  Doing so would make the division as large as Lear's $12.2-billion seating operation, which last year accounted for 76% of Lear's $16 billion in sales.  The growth, Rossiter said, will come through new business and acquisitions worldwide, but particularly in growing auto markets in Asia.  With the auto electronics market growing fast, Lear is provided with plenty of opportunity for successful acquisitions.

WardsAuto.com
All hands on DECS
(April 2008)

• Lear Corp. will manufacture seats within two years for two U.S. production vehicles using new technology that will cut the weight of the foam in half while making the seats more recyclable, comfortable and environmentally friendly. Lear is preparing to launch its Dynamic Environmental Comfort System seat, which represents a radical new approach to seat construction. Traditionally, one piece of petroleum-based polyurethane foam is attached to a metallic mesh and then integrated into the metal seat frame, Ash Galbreath, Lear's director-advanced materials and comfort engineering, explained at the SAE World Congress where Lear unveiled its DECS prototype, made of durable fabric produced entirely from recycled corn husks. The DECS approach replaces the metallic mesh with foam layers of varying rigidity. The first "durability" layer, attached directly to the seat-bottom frame, is made of expanded polypropylene. On top of that is the "dynamic comfort" layer made of Soyfoam, a soft, formable material manufactured from soybean oil and quickly ramping up in automotive seat applications. The third "tactile comfort" layer in the DECS seat consists of polyester foam, and the finish surface also can be made of whatever the customer wants- polyester, leather, etc. The material is 100% compostable. And unlike conventional polyurethane foam, all the materials used in DECS are easily recycled after the life of the vehicle.

The Detroit News
University High School steers teens to a career path
(March 2008)

• Tyreasha Bailey did not know much about automobiles before taking a manufacturing class at University High School. Now she's creating the interior of a vehicle on a computer, using a GMC Envoy truck as her model. Bailey and 30 of her classmates are taking the manufacturing class as part of University High's career pathways curriculum. But they're not just learning from textbooks, lectures and Web sites; they are gaining first-hand knowledge from Lear Corp. employees who spend one day a week for five weeks with the students. The employees take the students through the steps of a typical project assignment for an automobile: consumer research/marketing, color and trim selection, industrial design and final project presentation. The students will later demonstrate what they've learned before an audience.

Bloomberg
Lear wins appeal in suit over Johnson Controls patent
(February 2008)

• Lear Corp. won an appeals-court ruling that allows it to continue to provide Car2U garage-door openers to automakers until a Johnson Controls Inc. patent-infringement lawsuit is decided. A trial judge had barred Lear from selling the Car2U device, saying there was a good chance Johnson Controls and patent owner Chamberlain Group Inc. would win the suit. Closely held Chamberlain owns the patent and Johnson Controls is the exclusive licensee. The U.S. Court of Appeals for the Federal Circuit in Washington today said the judge erred in defining one of the key terms of the patent. The court threw out the order barring sales and sent the case back for further review. The dispute is over universal garage door openers that are incorporated into Ford Motor Co. vehicles and other cars. The judge had allowed sales of Car2U to General Motors Corp. to continue while Lear appealed his ruling. Lear says selling the product boosts Lear's electrical and electronics division, which made up 20 percent of the company's sales in 2007.

Automotive Engineering Interantional
Squeezing more out and in
(January 2008)

• Seats play a huge role in customer satisfaction, so it's no surprise that seat developers must respond to opposing requirements.  On one hand, engineers are trying to make seats thinner and lighter to provide more room and improve fuel economy.  On the other, they are following the trend to add more electronic functions. Cooling is augmenting heating, motors move lumbar supports into position after guiding seats into predetermined spots, and video screens reside in headrests and seatbacks.  This influx of electronics is occurring as engineers attempt to expand leg space.  "Even improving rare space by as little as an inch has shown to improve comfort scores dramatically," said Jeff Frelich, R&D Director at Lear. Automotive Engineering spoke to Lear about how the supplier manages these challenges especially in in an environment where once consumers realize the benefits they start asking for more.

FDi Magazine
Company Profile: Growth Trajectory
(December 2007/January 2008)

• As the in-play drama and financial dust settles at Lear Corporation in a post Icahn Enterprises takeover climate, Bob Rossiter, the man in charge and a 34-year Lear veteran, spoke to Financial Times recently about the outlook for Lear. Rossiter said Lear is looking at $15 billion+ in global sales in 2007 from its core businesses, with 2008 projected to be generally in line with that. Lear has narrowed its product line as it aims to be a world leader in its core businesses and pursues significant global expansion. Currently, Lear is focusing on its seating and electrical distribution businesses, where it has high market shares, and electronics, where it has the potential to be a niche player.  Lear is well positioned to grow in its $3 billion core electrical distribution and electronics business units, where the company hopes to double sales in the next few years, Rossiter says. Lear's global strategy is increasingly important as it seeks to offset declining market share and the lower sales of US domestics, which are hampered by declining sales of large pick-ups and SUVs.  Lear's China strategy is already paying off handsomely. The company has invested in 24 locations in China, including engineering centers and 19 manufacturing sites which are joint ventures, says a spokesperson.  Analyst Kirk Ludtke at CRT Capital Group says Lear is pursuing the right strategy in its global product development, seeking less reliance on the US domestics and building relationships with Toyota, Nissan, Honda, Hyundai and other Asian makers.  "I want to make a commitment to our customers and Lear people: we will be among the world leaders in our core businesses and among the most competitive auto suppliers in the world," Rossiter said. 

Industry Week
Lean takes the driver's seat at Lear
(December 2007)

• Like most companies in the U.S. automotive industry, Lear Corp. is always in search of ways to be more competitive. Lear recently talked to Industry Week about how it aims to build on its progress with a continuous improvement process that includes the adoption of lean manufacturing.  Lear has focused on four key areas of improvement -- housekeeping, quality, plant layouts and material flow -- that has already realized results at several facilities. Lear utilizes value-stream mapping to understand workflow and identify waste.  Even something as simple as switching from disposable to reusable containers resulted in a first-year package cost reduction of nearly 40%.

The Detroit Free Press
Fashion goes for a ride
(November 2007)

• Lear Corp. has recently announced the Aventino Collection, Lear's new line of premium leather which is inspired by current fashion trends such as quilting, bold colors, weaving, and personalization.  Lear hosted a fashion show at the Museum of Contemporary Art Detroit to unveil the new line.  At the show, models featured designs that were paired with miniature seats featuring the same fashion trends that corresponded with the models leather outfits.  Kylie Lockwood, a color and material designer from Ford said, "Moving away from gray, tan, and black is definitely a trend for automotive."  Ray Scott, president of Lear's North American seating business hosted the event and commented, "Everybody wants to personalize." 

Automotive News
Lear one of 23 finalists selected for the 2008 PACE awards
(November 2007)

• Lear Corporation's ProTec PLuS Self-Aligning Active Head Restraint System was selected as as one of twenty-three finalists in the 14th annual PACE (Premier Automotive Suppliers Contribution to Excellence) Award competition and Lear's SoyFoam received Honorable Mention by a panel of judges who recognize innovation by original-equipment suppliers in products and processes. Winners will be announced April 14 in Detroit. The awards are co-sponsored by Microsoft, SAP and the Transportation Research Center.

The Detroit Free Press
Rossiter has new resolve at Lear
(August 2007)

• In his first extensive interview since shareholders voted July 16 to reject Carl Icahn's $5.4-billion offer to buy Lear, Chairman, CEO and President, Bob Rossiter, talks bullishly with Detroit Free Press columnist Tom Walsh about Lear's future and how he is re-energized and ready to lead Lear into a new era of strong growth. Following strong second-quarter earnings of $123.6 million, Rossiter predicted that Lear will make money in the second half of this year, despite sluggish overall car and truck sales in the United States and predicted Lear will "make some major moves ... for acquisitions to strengthen our electronics business and expand our foothold in Asia." Now that the company's turnaround plan has gained traction and profits have been restored, Rossiter said he's confident in the company's future.
  Automotive Engineering International
  

2007 SAE Tech Award
(April 2007)

• The Car2U Home Automation System (HAS) from Lear was named by Automotive Engineering as one of the more innovative new products on display at SAE this year. HAS is a universal remote control device that uses Z-wave wireless mesh technology for users to operate garage doors, home appliances, and lighting from their vehicles. The Car2U HAS device can be packaged inside vehicle overhead consoles or on sun visors for access by the drive, and General Motors is offering the system as optional equipment on more than two dozen 2007 model year vehicles. The HAS uses an antenna design to achieve a working range up to 650 feet (200 m) and features a technique to preserve battery life. Z-wave radio frequency technology connects stand-alone devices into an intelligent network that can be controlled and monitored wirelessly. The system takes less than 30 seconds to program for garage door openers with a rolling code; accessories include control modules for home indoor and outdoor lights, dimmer switches, small appliances and thermostats.

Automotive Design & Production
Soy Oil for "Greener" Interior Foam
(January 2007)

• Lear Corp. said it is using chemistry and other scientific processes to transform farm crops to industry products at Lear as they work toward more environmentally sound products and processes. A case in point is the company's alternative to traditional polyurethane foam for seating. Although the company is deploying expanded polypropylene for some applications (e.g., the rear bench of the '06 Chevy Impala and the rear bolster for the Ford Five Hundred), they've taken a page from Henry Ford's book and are working with soybeans to create the polyol that's mixed withisocyanate to create the foam. The polyol is not purely soy oil, but a blend consisting of petroleum-based polyol, soy polyol, catalysts, surfactant, and a blowing agent. Ash Galbreath, director of Environmental Comfort & Engineering, explains Lear is producing the foam for applications including head restraints, arm rests, and seating surfaces' overall, there are 30 to 40 lb. of foam used in a vehicle interior, there is a mixture of 60% polyol and 40% isocyanate. Of the polyol blend, up to 50% soy oil content has been validated to have the required foam properties for auto manufacturers. In addition to the fact that soy beans are a renewable resource unlike petroleum, there are other environmental advantages. There is a 100% reduction in CO2 emissions and 50% to 60% lower energy required in transforming the beans into oil as compared with processing petroleum. What's more, there is the potential of reducing as much as 2/3 of the volatile organic compound emissions associated with creating the foam (apparently, there are no free amines after foaming as there are when conventional petroleum-based foams are produced).
  

The Detroit Free Press
SUPPLIERS AT AUTO SHOW: Time to snoop on rivals' stuff
(January 2007)

• The Detroit Free Press accompanied Lear product executives on a review of the 2007 North American International Auto Show to learn what suppliers look for in the vehicles featured in the million-dollar exhibits at auto shows. The result: engineers from Lear Corp. will be mulling over their own photos and observations from the auto show to see if they are keeping pace with technological innovation and developments by their competitors, since Lear competes with its rivals for large-scale interiors contracts. The NAIAS's industry days give Lear researchers an opportunity to gather information on competitors and in some cases, extensive analysis and benchmarking clinics to see how a certain product was developed. The Lear executives checking out this year's auto show preview for the first time shared what they look for in competitors and highlighted trends they're noticing in interior design, such as: Stitching with contrasting-colored thread on seat seams and vans that promote a family feel such as child booster seat or the Ford's Airstream concept's interior resembling a living room.