Your partner for high-quality, high pressure andgravity casting products in aluminumAluminum Automotive Components

The companyThe perfect combination of innovation and tradition

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Dependability, permanence, professionalism and quality are

increasingly important to maintain a competitive edge in an

ever-accelerating commercial world.

We focus our attention to ensure we have a solid financial

base. Corporate financial stability and transparency are key

prerequisites for long-term partnership.

Our level of engagement with the business guarantees

fast decision making and at the same time, raises motivation

and commitment.

We see ourselves as a socially responsible business,

caring for our employees as well as the environment.

We encourage a working atmosphere characterized by

openness, team spirit and drive.

Ever since the firm was founded almost 50 years ago, our

philosophy has been that delivering high quality, innovative

products requires a constant technological and human

challenge. We refuse to be satisfied with our achievements

and we work strictly to the “Bocar DOL principle”:

Disciplina, Orden, Limpieza (discipline, order, cleanliness).

Our ongoing investment in high-end technology and our

locations in Mexico allow us to provide excellent quality

at a competitive price.

This makes us – beyond NAFTA – one of the world’s leading

providers of aluminum components for vehicle engines,

transmission and structural components.

The BOCAR Group: BOCAR, PLASTIC TEC and AUMABocar Group was established in 1967 in Mexico City,

originally as a manufacturer of pumps and carburetors.

Today we have three strategic business divisions, primarily

serving the international automotive industry. They are:

BOCAR: Bocar’s focus is the manufacture of high-quality

plastic, aluminum precision parts and complex assemblies

for automotive applications. We place a special emphasis

on our ability to combine different materials, such as plastic

and light metal. Bocar headquarters also has a development

division.

PLASTIC TEC: Plastic Tec develops and produces plastic

injection-molded parts for automotive interiors, trunks,

exteriors and engines. Highlights include multi-component

injection molding, in-mold film coating, textile insert

molding, interior painting and gas-assisted molding.

AUMA: Develops and produces aluminum products along

with aluminum gravity casting. Applications are: vehicles

engines, steering, transmission and structural components.

This division also handles complex assemblies and

functional testing as required.

As a group, we are able to offer the automotive industry

– and other sectors – a sophisticated range of products

and services. We are both a development partner and full

service supplier capable of producing aluminum or plastic

series products to specified requirements. This places

us amongst a few companies capable of supplying hybrid

solutions in plastic and aluminum.

Customer proximityFor technology that’s made-to-measure

We build bridges to our customersLong-lasting business relationships – our benchmark for customer satisfaction

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References Awards

American Axle

Audi

BMW

Bühler Motor

Borg Warner

BRP Rotax

Chrysler - Fiat

Daimler

Delphi

Dräxlmaier

Faurecia

Federal Mogul

Ford

GM

Honda

Jatco

Magna

Mazda

Nexteer

Nissan

Remy

Robert Bosch

Seat

Skoda

Toyota

Trelleborg

Valeo

Volkswagen

ZF Group

Audi

Chrysler Excellence

Chrysler Gold Award

Ford Q1

Ford Full Service Supplier

GM Global Supplier of the year

Honda Productivity

Nissan Excellence

Nissan Quality Master

Nissan Zero Defect

VW Group Award

America

Mexico

BOCAR

(Mexico City)

BOCAR

(Lerma)

AUMA

(Chihuahua)

AUMA

(Saltillo)

AUMA

(San Luis Potosí)

AUMA TEC

(Queretaro)

FUGRA

(Lerma)

PLASTIC TEC

(Mexico City)

PLASTIC TEC

(Lerma)

PLASTIC TEC

(San Luis Potosí)

PLASTIC TEC

(IMD Lerma)

USA

AUMA ENGINEERED

LOGISTICS (Manchester, TN)

AUMA ENGINEERED PRODUCTS

(Detroit, MI)

Europe

Germany

BOCAR GmbH

(Wolfsburg)

BOCAR GmbH

(Stuttgart)

Asia

Japan

BOCAR AP

(Yokohama)

Today, with over 6,000 employees, 11 production facilities in

Mexico, and development offices in Mexico, USA, Germany

and Japan, the Bocar Group offers its customers a global

network.

The way that we are structured globally is designed to provide

our customers everywhere with completely consistent

processes. We plan to expand our global footprint step by

step, so that we will always be right where our customers

need us as a partner.

The scope of our servicesFrom initial idea to finished product

Our products generally have to stand the test of time in

very different global markets, and very diverse conditions.

What’s more, development lead times are ever shorter and

cost pressures continually increasing.

That’s why “full service” and “frontloading” are more than

just catchphrases to us. They mean performance across the

entire product development process, and a consolidated

single-source value chain under one roof, without lengthy

processes or delays – flexible, efficient, green and

customer focused.

We maximize our expertise by combining our extensive

skills in handling aluminum with a focus on introducing

the latest technology into our production processes

and how we develop them going forward. The issue of

lightweight construction, especially, is constantly gaining

importance. We guarantee problem-free processes, and as a

development partner we offer our customers an end-to-end

concept from design and engineering, through production to

aftermarket.

The Bocar Group has over 60 design stations, and the

development cycle is monitored through to production.

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From design to production

Design Engineering & product develop-ment

Prototypes In-house tool shop

Component checking and certification

Production Quality Service

Design stage support

Animation and design

visualization

Image processing

Reverse engineering

Advice on materials

Engineering and installation

space research with Catia

V5, Pro-E, UG-NX

Topology optimization and

simulation with Opti-Struct,

Abaqus, Fluent, Hyperworks

and Hypermash

Process simulation

(Magma, Fluent)

Product cost optimization

FMEA

Acoustics (LMS)

Rapid prototyping – laser

printing

Cold box sand casting –

furan resin

Machining

Assembly

Leak testing

Function testing

Tool and equipment

fabrication

Clamping concepts for

machining and assembly

Tool maintenance

In-line re-tooling

Salt spray chambers for

corrosion resistance testing

Engine test bed

Test benches for water and

oil pumps

Test bench validation

Durability and lifetime

requirements testing using

shakers and vibration test

benches with climate chamber

Laboratory-based materials

analysis

AL die casting

AL chill casting

CNC machining centers

Complex assemblies and

function testing

Leading-edge washing and

drying facilities

Spark erosion deburring

Metallography and analytics

X-ray facilities

Computer tomography

CMM Zeiss with 3-D

scanning (Hollox), optical

measurement (GOM)

EMPB (initial sample

inspection)

Internal and external training

Customer support from

product concept stage

onward

On-site customer field

service engineer.

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All concept models and benchmark series components

undergo exhaustive and highly accurate testing and

qualification by our prototyping division. The results are

fed straight back into engineering and simulation.

This is also how we ensure that all of our series products

are optimized, and that perfect components are delivered

at the right time and place.

Our rapid prototyping and sand casting processes mean

that we can achieve the shortest possible development lead

times.

We can conduct fast and thorough requirements testing in

state-of-the-art laboratories, including:

Fatigue and thermo-mechanics tests

Load and thermal tests

Vibration and noise measurements (NVH)

Corrosion testing in salt spray chambers

Engine test benches that can also simulate sea levels

Pilot and batch production in testing and implementation

as well as on the production line

Test laboratories and equipmentVerification of engineering processes

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In-house tool shop

All of our tools are continuously tested and always

up to date.

Our specialists work closely with our customers to agree

on tool engineering requirements for prototype and series

products, and with major external suppliers to fulfill them.

Every one of our plants has its own fully equipped tooling

facility, enabling us to carry out and to a high standard all

of the necessary maintenance, repairs and modifications

in-house.

On the development side, we focus on commercially implementable

solutions offering real competitive edge and added value.

To take full advantage of global knowledge, to transfer it within

the business and to guarantee consistent quality levels worldwide,

we continually optimize our systems and keep all of our locations

equipped with the same, standardized tools. And it goes without

saying that we use the latest development tools and systems,

including CATIA, Pro-E, Unigraphics-NX, CAE/CFD simulation,

FMEA, product development process, simultaneous engineering

and prototyping.

Design and product developmentExpertise, persistence, creativity

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QualityThe best is only just good enough for us

Quality is “the” key prerequisite for our future as a

business. It is the foundation on which our customers

lay their trust, and therefore, on all of our activities. The

whole organization, and every employee, is focused on

this benchmark. Quality management is our number one

management task.

All of our production processes are designed around a

zero defect target strategy. The latest technology, globally

consistent standards and a mature process chain allow us

to strike the balance between the best possible quality on

one hand, and competitiveness on the other.

It is also absolutely critical that every employee – from

management to the worker on the line – is committed.

Because quality begins with people, not things. Preventive

maintenance and TPM (Total Productive Maintenance) also

contribute here.

In our approved laboratories and measuring rooms, which

are equipped with high-precision measuring devices,

we carry out materials testing using X-ray and mass

spectroscopy, as well as metallographic analyses.

Oxidation, corrosion and residual dirt requirements are fully

covered by washing and drying facilities with pressures of

up to 1,000 bar.

We are never satisfied with today’s achievements – we

work continuously to improve our quality and management

systems. All of our processes and procedures are designed

so that we can react quickly to meet customer requirements

all over the world – without compromising quality. So we

work very closely and openly with our customers in the

automotive industry. We assign every customer with clearly

defined contact persons and procedures. An expert team

of internal and external specialists regularly evaluates our

performance.

Our quality system is up to date with ISO TS 16949 and ISO

14000 standards.

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ProductionLean and efficient – for your success

Bocar and Auma are optimally equipped with over 400

CNC machining centers, modular production lines and leak

tests. The Auma plants have over 100 high pressure die

cast machines (HPDC) with a locking force of between 50

and 2,200 tons. The aluminum chill casting plant has over

50 production cells. We also carry out heat treatment on a

range of products.

Bocar Group production and logistics processes are based

on lean manufacturing to enable us to meet customer

requirements. The Bocar Production System is integral to

our corporate culture, ensuring that our product processes

are optimized. We train our employees regularly, embedding

the Bocar culture in both their knowledge and actions.

Flexibility

Value orientation

Synchronization

Transparency

Perfection

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ISO TS 16949 ISO 14000

AUMA AUMA

A wide product portfolioThe right solution for every need

Requirements in the auto industry are becoming complex

and extensive. Here at Auma, we are able to develop

and produce perfected automotive sector products and

solutions with maximum functionality, regardless of whether

we are working with our customers purely as a supplier, or

as a system partner.

We are meeting the latest requirements – for lightweight

construction technology for example – using topology

optimization software, which also allows us to make our

contribution to environmentally friendly mobility. Our broad

spectrum of customers, processes and markets means that

our product expertise just goes on improving with time.

Today, our product range includes: oil pans, control

housings, intake manifold components, VTC housings, water

and oil pumps, transmission housings, cylinder head hoods

and components with oil separation systems, housings for

solar inverters, engine mountings, structural components

for body construction, etc.

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Rear Axle Cross Members Console Shock Absorbers Convertor Bells

Brackets Oil Pan Differential Carriers

Rack & PinionsFront Covers Cover SidesOil Pans

Engine components

Structural components

Transmission components

Steering System

Recruitment and career entry

We offer young recruits, an opportunity to develop their

practical skills through internships in diverse areas as well

as studying at cooperative universities. We integrate them

into project teams for on-the-job training, supported by

experienced employees. The training program covers basic

skills, maintenance, CNC machinery operation, electronics

and robotics.

Our goal is that qualified employees should be brimming

with enthusiasm for the company’s diverse tasks.

PeopleOur most important resource

The automotive industry is characterized by constant

change, a fast pace and a high innovation dynamics. We

develop and motivate our people in a very focused way.

They are the foundation of our work and performance, and

our success is driven by their high level of engagement with

tasks and projects. What counts for us is this: everyone

has strategies and machinery – it is people who make the

difference.

We encourage day-to-day togetherness, engagement,

openness, trust and loyalty. Our aim in doing so is to

achieve outstanding performance, sustainable expertise,

and personal responsibility.

Pleasant working conditions and targeted education and

training opportunities are our highest priority. This starts

with all our plants having their own training facilities, and

goes on to include exchange programs – with our

international operations – and alliances with other countries,

institutions and universities. Last but not least, we develop

our specialists in their fields, and run separate management

development programs in self-management, leadership and

sales.

The majority of our young talent is trained in-house. Every

plant in the Bocar Group has its own training workshops,

where we train our young technicians according to our

apprenticeship program.

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AUMA Engineered Products, K.K.907-B Queen‘s Tower A3-1, Minatomirai, 2 Chome, Nishi-kuYokohama, Kanagawa220-6009 JapanOffice : +81 (045) 319 6167E-mail: info@bocar.com

AUMA Engineered Logistics161 Volunteer Pkwy Manchester, TN 37355USA

Office: 931 728 8853 E-mail: info@bocar.com

AUMA Engineered Products, Inc.47140 Cartier DriveWixom, MI 48393-2876USA

Office: +1 (248) 668-4919E-mail: info@bocar.com

BOCARCruz Verde 169-1ALos Reyes Coyoacan04330 Mexico, D.F.MexicoOffice: +52 (55) 5422 2300E-mail: info@bocar.com

BOCAR GmbHHeinenkamp 2638444 Wolfsburg-HattorfGermany

Office: +49 (5308) 402 400E-mail: info@bocar.com

BOCAR GmbHMax-Lang-Straße 56/270771 Leinfelden-EchterdingenGermany

Office: +49 (711) 440 928 0E-mail info@bocar.com