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11North America January/February Spotlight Volt, Explorer take top honors at Detroit auto show This year’s North American International Auto Show in Detroit made a splash with a renewed sense of optimism for the industry and 30 new vehicle debuts. In addition, the winners of the 2011 North American Car and Truck of the Year were announced, crowning this year’s most significant new vehicles. The Chevrolet Volt and the Ford Explorer each were distinguished from a field of more than 30 vehicles. Both of these vehicles feature Faurecia products. Continued on page 8 2 GM and Faurecia, growing closer 4 Innovation grabs attention at LA Auto Show 6 Q&A with Shannan Triplette faurecia infos NA • Jan/Feb 2011 2 Group News GM and Faurecia, growing closer After bankruptcy and government rescue, the new General Motors is smaller, more nimble and back to profitability. The Detroit legend also has ambitious plans for the future … with Faurecia as a partner. F aurecia often organizes customer Tech Days, but a recent meeting in Auburn Hills, Mich. among General Motors, Faurecia Interior Systems and Automotive Seating was especially memorable. Not only was it held at the request of the customer, with a worldwide agenda and executive management from both companies attending, it was also followed by very promising developments. Behind the Tech Day invitation is GM’s search for technological solutions that will help differentiate it from competitors – a strong sign that GM believes Faurecia can provide added value. Exclusive offer Feedback from GM has been excellent. Follow-up meetings for implementing new products such as LOCOP (low-weight covering premium) have already started. Moreover, the customer requested another Tech Day specifically to assess Faurecia’s electrical capabilities, during which Faurecia displayed the SmartFit™ innovation, and Infoskin and Centerstack (Interior Lighting and HMI Solutions) to the customer. (See related story on page 4 and 5). GM wants to work with Faurecia earlier in the production process, incorporating new products into its early designs. It also has offered to work exclusively with Faurecia if the technology put forward is particularly innovative. Faurecia now expects to produce several new products that will strengthen GM’s position in a given market and provide long-term benefits to both companies. The 2011 Chevrolet Equinox SUV features IP and seat frames and mechanisms by Faurecia LOCOP (low-weight covering premium) Leading in every category I n 2010, Faurecia acquired four companies. These actions illustrate Faurecia’s development priorities – to reinforce its business activities and achieve technological leadership. It started in February with EMCON Technologies, which allowed Faurecia to become the leader in emissions control technologies. At the end of March, it was Plastal Germany’s turn to join Faurecia, followed by Plastal Spain at the end of September. This resulted in Faurecia Automotive Exteriors capturing the number one ranking in the sector in Europe. In October, the Group purchased a division of Hoerbiger that produces pneumatic seat comfort systems, mainly targeted at the premium vehicle segment. And finally, at the end of November, Faurecia announced the acquisition of Angell-Demmel Europe. The company’s decorative metal design elements further strengthen Faurecia’s offerings in automotive interiors. Adding to the FAE footprint in China According to the wishes of our customer FAW-VW, Faurecia Automotive Exteriors is about to create a joint venture (JV) in China to manufacture bumpers for the Audi A6. Faurecia is joining forces with the Chinese company Huaxiang’s subsidiary firm, Ningbo Huazhong, to create this joint venture, with each stakeholder holding 50 percent. Management of the shared company will be carried out by Faurecia. The JV is also taking over the production of the Magotan, the Chinese version of the VW Passat, currently produced by Huaxiang. This JV, the first in a long line, allows FAE to establish a foothold in China, which is a strategic market for the Group. 3 Site Life New EAP ‘teams’ up with employees Faurecia has a new Employee Assistance Program called TEAM. It offers 24-hour confidential resources for employees and your families, including: • counseling • coaching • community resources • referrals • crisis intervention • and more As part of Faurecia employees’ benefits, the TEAM EAP is a free resource available online at team-eap.com or by calling toll-free (800) 448-8326. There are no copays or deductibles due for using TEAM. Services are paid for by Faurecia. Some of the services offered include child care and elder care recommendations and information, financial counseling, legal aid, articles, assessments, book references, links and information about local resources. TEAM respects all employees’ rights to privacy. Confidentiality is respected and assured. FIS to open plant in Louisville Faurecia Interior Systems will open a new manufacturing facility in Louisville, Ky. to produce various components for upcoming vehicle models. In March, the company expects to take occupancy of the new facility, located at 2000 Stanley Gault Parkway. The site complements the business group’s existing footprint in North America and will support new customer programs. It is expected to reach full production in 2013. Faurecia to acquire JCI Madison plant This spring, Faurecia Automotive Seating will acquire the Johnson Controls plant in Madison, Miss. The plant, with 250 employees, supplies complete seats for vehicles assembled at Nissan’s Canton, Miss. plant, including the Altima, Armada and Titan. The Madison facility will complement Faurecia’s existing North American operations as the company continues to broaden its customer base and expand its operations in the Southeast United States. “Faurecia is eager to expand its business with Nissan,” noted Rich Kolpasky, President of FAS North America. “We look forward to a prosperous future in Madison.” Fraser awarded for Best Plant Performance by FIS Personnel changes made Several personnel changes were announced at the end of 2010 and beginning of 2011. Here is a round-up of those updates. NACC Mark Schmink has been named Group Country Vice President of Human Resources for Canada and the United States. He is now fully dedicated to Group Country HR, in order to address the challenges facing the region. He is based at the Troy, Mich. Technical Center. FECT Tom Hack has been appointed the Vice President of Quality for FECT NAO. He was previously the Director of Quality for the Division. He most recently was the interim Plant Manager at the Gladstone facility in Columbus, Ind. Steve Millon was named Plant Manager of the FECT Gladstone facility in Columbus, Ind. He rejoins Faurecia from Dunham-Bush in Kuala Lumpur, Malaysia, where he was the Director of Operations. Larry Bradley has been named Plant Manager at the new FECT Chattanooga, Tenn. site. FAS Denis McAuliffe has been named Vice President of Purchasing, Program Management and Serial Life Management for the North America Division of FAS. He was previously Vice President of Purchasing for FAS. Scott Cieslak has been appointed Vice President of Finance for the North America Division of FAS. He previously held the position of Director of Divisional Controlling for FAS NAO. Jean-Luc Daudon is acting as interim Vice President of Quality within the North America Division of FAS. He will support the Division in its recovery plan. Daudon continues to hold the position of Vice President of HSE & Quality for the Business Group. Dean Woods has been appointed Vice President of Human Resources for the North America Division of FAS. He previously held the position of Group Vice President of Employee Empowerment. Eric Van Camp has been appointed Vice President of Sales for Asian OEMs within the North America Division of FAS. He previously held the position of Director of Sales for Nissan for the division. Matthias Siemer has been appointed Vice President of Sales for German OEMs within the North America Division of FAS. He previously held the position of Director of Sales for German OEMs for the division. In December, Vice President of North America Operations for FIS Jon Gregory presented the Fraser, Mich. Technology Plant with an award as the best performing FIS plant worldwide for 2010, during the plant’s monthly Town Hall meeting. The award was originally given during the FIS Annual Convention held on November 8 in Barcelona, Spain. Jean-Michel Renaudie, President of FIS in North America, and his staff were also present at the ceremony in Fraser. Renaudie told the whole Fraser organization that, “This award for the best performing FIS plant worldwide is very well deserved. You can be proud of your performance, and my team and I are very proud of your accomplishments.” Fraser received the award based on these criteria: FES Audit score, production inventory management, manufacturing costs, indirect labor cost management and internal material productivity. NAO represented well at FIS awards Several awards were presented at the FIS Convention in November. North American teams and innovations were among the nominees, including: • DecoStitch for the Innovation Award • Ford Fiesta (B299) for the Program Award • Cadillac ATS for the Acquisition Award In addition to the Fraser Plant win (see story above), GM Worldwide was named the best Customer Account. Jeff Telder, Vice President of the GM Customer Division, FIS, received the award on behalf of the entire team. “This award is a direct result of the team’s hard work, the outcome of which is a strong and successful business relationship with General Motors,” said Telder. “We are committed to further strengthening our efforts and will support our mutual growth around the world.” faurecia infos NA • Jan/Feb 2011 4 Zoom Innovation grabs attention at LA Auto Show SmartFit™ customizes comfort and safety At this year’s Los Angeles Auto Show, one of Faurecia’s innovations drew attention from both the automotive and technology fields – SmartFit™, the phone-activated seat adjustment system. This application (app) concept takes the guesswork out of properly adjusting seats. It’s designed for smartphones and can automatically adjust the vehicle’s seats to conform to the healthiest position for each occupant, controlling the seat wirelessly through a system like Bluetooth. Faurecia innovators demonstrated how the app works using a 22-way power seat from the Audi A8 – one of the most complex seats on the market. They anticipate SmartFit can be ready for 2014 or 2015 model year vehicles. How it works The first step for the custom adjustment involves getting the user’s measurements. SmartFit guides the user through an easy-to-follow process for creating a digital model of his or her body. The user types in his or her height and weight. Then, someone takes a photo of the user SmartFit fulfills the consumer’s wish for improved wellness by creating a seat-tailoring system designed by ergonomic experts. sitting down. This is done with the smartphone. The application then directs the user to extend an arm to the side and swing it up and down. All of this data is fed into a Faurecia server, and using the Group’s expertise developed from years of testing and development, the perfect settings are calculated. The tailored fit is then sent wirelessly from the database to the phone to the seat, which automatically adjusts itself. Individual profiles for each occupant can be stored in the seat’s memory. Why is there ‘an app for that’? SmartFit will reduce the complexity of the seat by using a device that occupants already bring into their vehicles every day. Redundant components could be eliminated, which would reduce weight in the vehicle and the use of chemical-based materials. In addition to these Clean aspects, SmartFit will support healthy posture for drivers. It will improve overall comfort, thereby reducing potential distractions that might otherwise result as drivers readjust their seats to find a comfortable position. SmartFit fulfills the consumer’s wish for improved wellness by creating a seat-tailoring system designed by ergonomic experts. The benefits of SmartFit could also include increased customer satisfaction for automakers. Occupants will be able to take full advantage of advanced comfort systems, which could raise satisfaction scores. No longer will consumers get confused by multiple controls. Nor would they need to struggle as they drive to find the best adjustment for their body. SmartFit will automatically customize the seat just for them. A ‘Clean’ start Innovations destined to move from LA Auto Show to highways As new-generation vehicles have moved from concepts to consumers, Faurecia has supported their evolution by developing lightweight systems. This Clean start has the auto industry considering space, materials, comfort, efficiency, safety, quality and appearance. As a result, automakers are rapidly adopting Faurecia Clean innovations like those displayed at the 2010 Los Angeles Auto Show. In the months to come, these systems and concepts and others will move steadily from the show floor to the nation’s highways – reducing fuel consumption and helping make possible a new generation of cars and trucks. Lightweight, recyclable sustainable comfort This new generation of super-thin seatbacks and cushions replaces traditional steel and foam components with lighter and more easily recyclable materials. The composite seatback is 15 percent thinner than the industry’s thinnest, adding to a cabin’s volume. This allows designers to add legroom or even shorten the overall length of a vehicle. The performance cushioning that is used with the thin seatback is cleaner and healthier than current ‘state of the art’ seat cushioning. The thermoplastic elastomer padding incorporates features that interface with the seat frame, soft cover, suspension systems, comfort adjustments, climate systems and other controls. These materials create a seat that is more comfortable and durable than conventional seats that use foam. Exhaust heat recovery for hybrids and plug-ins As the auto industry transforms much of its fleet to more environmentally responsible hybrid electric and plug-in electric vehicles, Faurecia is already far up the road with new emissions control technologies to improve performance and fuel economy. For instance, hybrids must run the internal combustion engine longer to heat the cabin effectively because electric engines do not generate heat. Faurecia’s Exhaust Heat Recovery System takes heat quickly from the combustion engine’s exhaust. This capability can reduce the amount of time that the engine must run to sufficiently heat the cabin by as much as 50 percent. 5 faureci•ol•ogy: Clean “Clean” intensifies the idea of “green” to sharply focus on weight reduction, incorporating lighter and more environmentally suitable materials and natural fibers inside, outside and under the car. With lighter-weight seats, emissions control technologies, interiors, front ends and acoustics systems, coupled with an emphasis on using recyclable materials, Faurecia’s Clean initiative is helping contribute to a more responsive and responsible auto industry. SmartFit connects your seat functionality to your smartphone. Thermal Enhancer™ reduces diesel fuel needs To respond to the needs of diesel trucks, Faurecia has advanced the ActiveClean® Thermal Enhancer™. This device is a small combustion chamber where precisely measured quantities of diesel fuel are injected and burned when not enough natural exhaust heat is available for regeneration and efficient catalytic operations. ActiveClean operates at 80 to 90 percent efficiency, requiring much less extra fuel than conventional diesel heating methods. Low-weight covering premium (LOCOP) instrument panel skin This cut-and-sew solution offers the soft touch feel of polyurethane covering material yet is much lighter in weight and more easily recycled than traditional fabric. It lowers the weight of the IP by about 20 percent (200-300g) and reduces costs by 20-35 percent. The material can also be removed in one piece, at the end of the life of the vehicle, and is easily ground up so it can be made available for reuse, rather than sent to the landfill. Thermoplastic liftgate This breakthrough product has elevated ease of use and slashed the weight of the tailgate. Instead of producing the liftgate with steel, it is molded from thermoplastic, painted and equipped with foam inside the door for sound deadening. Weight is reduced by up to 40 percent and OEMs can save up to 70 percent on tooling. Designers also have more freedom in shaping the liftgate. It will integrate rear window, spoiler, structures and panels. For more information, visit faurecialaautoshow.com on the web. faurecia infos NA • Jan/Feb 2011 6 In Short Q&A Fiat 500 Shannan Triplette, Vice President of the Chrysler & New Domestics Customer Division, FIS NAO The release of the Fiat 500 will mark the launch of the brand in North America. What was it like working with Fiat on this project? This project was unique to Faurecia Interiors because it was not only the first time working with a combined Fiat/Chrysler organization product team, but the program was also developed in a very short and challenging 14-month time frame (from award until launch). Being part of the first joint Fiat/Chrysler product development extended team was very interesting and exciting for everyone at Faurecia in both Auburn Hills and Puebla. Seeing the Italian and North American teams come together for a common goal was a real pleasure. What are some of the innovations on the 500? Are these Fiat or Faurecia innovations, or collaboration between both companies? In terms of true innovations for North America, Faurecia Interiors developed a brand new high gloss paint line in Puebla for the body color interior trim panels that we previously only had product manufacturing experience with in Europe. We also worked very closely with the combined Fiat/Chrysler team by tailoring the Fiat 500 instrument panel and console original European design to the North and South American markets. This included adding a new glove box, passenger side airbag system and newly designed console features. Were there any challenges that the team encountered with the launch of the vehicle? If so, how did Faurecia overcome them? There were several challenges that the team encountered, both leading up to and during the launch itself. Because of the short product development timing, many of our tools arrived very late relative to the start of production to our home lines in Puebla and our supply base respectively. This was very challenging because it gave us very little time to tweak and tune our processes to ensure top quality and a proper level of production volume. Another, and perhaps the largest challenge, was the launching of the new high gloss paint line and developing the proper painting methodology for the 16 separate paint color variants required by the customer. These challenges were eventually overcome by tapping into the global resources available to Faurecia in terms of poles of competence, FES tools utilization, supplier quality and thousands of man hours of dedicated professionals in Puebla, Auburn Hills and other supporting sites. How is it working with Chrysler and Fiat as they blend their companies? On the 500, is there a clear distinction between the two companies, or are they working together as one unit? Seeing how these two customer organizations came together and brought experiences and individual expertise to the table was impressive. Making a vehicle that was developed for the European market fit into the North and South American markets demanded that they blend their respective visions and ideas together as one unit, without loosing its roots. Faurecia also supplemented this with our contributions to the instrument panel and console developments. I feel this fun yet well-executed small car will show consumers that the combination of Fiat, Chrysler and Faurecia is a winning combination and will sell well once it hits the showrooms in early 2011. 7 Industry News 2012 Fiat 500 U.S. starts to show less appetite for gasoline Italian style blended with world-class craftsmanship T he new 2012 Fiat 500 represents a new approach to personal transportation, with its modern and simple design aestethic, numerous personalization options, fashionable Italian flair and world-class craftsmanship. “The Fiat 500 is an icon of efficient personal transportation,” said Doug Betts, Chrysler Group Senior Vice President of Quality. “It is an excellent package to start with. As we enhanced it to match North American driving conditions and consumer expectations, we also made sure to preserve the world-class fit-and-finish standards achieved by Fiat’s development team.” For the new 500, simple does not mean “bare.” The passenger compartment is airy and roomy, an environment designed to be comfortable and enjoyable for any destination. “The interior design is space-efficient and stylish, while delivering absolutely everything that is required and nothing more,” said Roberto Giolito, head of Fiat Style. “The interior design perfectly balances practicality with comfort and convenience features while infusing Italian-by-design style and personalization options.” The instrument panel (IP) continues the perfect blend of modern simplicity with iconic Italian styling. The upper IP is designed to convey a sense of refinement and elegance and features color-matched exterior accents for added detail. Frequently used vehicle buttons are highlighted with chromed circular rings and centrally located. The lower IP highlights new space utilization with large- and small-sized storage spaces. Faurecia is a key supplier for the Fiat 500, including for the interior. The Puebla, Mexico Plant supplies the instrument panel and center console. The FAS facilities in San Luis Potosi, Mexico and Bradford, Ontario supply the tracks and recliners. And the complete exhaust system is produced at the FECT plant in Querétaro, Mexico. After seven decades of mostly uninterrupted growth, U.S. gasoline demand is at the start of a long-term decline. By 2030, Americans will burn at least 20 percent less gasoline than today, experts say, even as millions more cars clog the roads. The country’s thirst for gasoline is shrinking as cars and trucks become more fuel efficient, the government mandates the use of more ethanol, and people drive less. According to the National Resources Defense Council, by 2020, improved fuel economy is expected to lower annual carbon dioxide emissions by 400 billion pounds, the equivalent of taking 32 million cars off the road. In reality, there will be 27 million more cars on the road — a total of 254 million — a decade from now, according to government projections. Source: The Detroit News Automakers commit to exporting to China During the visit of Chinese President Hu Jintao to the United States in January, General Motors and Ford Motor Co. released details of plans for exporting to China. GM said it plans to export $900 million in vehicles and parts to China under a two-year agreement signed with its flagship joint venture, Shanghai GM. Exports will be worth $500 million and components worth $400 million under the agreement. Ford signed an initial agreement to explore the possibility of exporting vehicles to China, part of a multi-billion dollar commercial pact. Ford, a relative latecomer to China, has been accelerating its expansion in the world’s largest auto market. It is building a new car plant with its partners Chongqing Changan Automobile Co. and Mazda Motor Corp., and, at the same time, adding a $300 million new facility jointly with partly-owned Jiangling Motor. During the next four years, Ford intends to introduce 50 new products and powertrains in Asia and Africa. Source: Automotive News and The Detroit News DIMENSIONS INTERIOR • • • • • An artistic blend of clean lines and conveniently located features • Exterior color-matched upper instrument panel • 14 seat color and material combinations • Chromed “hook” door handle pays homage to one of the most iconic elements of the original 500 • Upgraded heating and cooling system • Redesigned front seats feature new armrest and seat cushion for improved comfort • New steering wheel controls and new premium audio system Length: 139.6 inches Width: 64.1 inches Height: 59.8 inches Wheelbase: 90.6 inches ENGINE • 1.4-liter, inline four-cylinder engine that delivers 101 hp and 98 lb.-ft. of torque EXTERIOR • Available in the Pop, Sport and Lounge models • Iconic Cinquecento cues like short overhangs, a “shell-like” roof and “whiskers and logo” face • Bi-halogen headlamps, lower fog lamps and a new signature, chromed license plate brow • 16 paint colors SAFETY • All-new air bag system with seven standard air bags • Reactive head restraints • Standard electronic stability control that integrates electronic brake-force distribution, anti-lock brakes and traction control systems American cars are back at last American carmakers earned higher scores in 2010 than imported cars in separate J.D. Power surveys of initial quality and owner satisfaction. American products, overall, are now at least neck-and-neck with foreign competitors. “All three of the domestics have improved quite a bit over the past few years in initial quality, but Ford has been more consistent and more notable,” said David Sargent, Vice President of Automotive Research at J.D. Power & Associates. In J.D. Power’s most recent APEAL survey, a measure of how happy owners are with their new cars, GM tied Ford’s average score of 794 out of a possible 1,000. Both exceeded the overall industry’s average score of 778. Source: CNN faurecia infos NA • Jan/Feb 2011 8 Spotlight Volt, Explorer take top honors at Detroit auto show Continued from page 1 Car of the Year For 2011, the Chevrolet Volt garnered more votes than the Nissan Leaf or Hyundai Sonata, which were also finalists. “It’s a great honor to be recognized as the North American Car of the Year,” said GM CEO Dan Akerson. “Such recognition provides customers with credible, expert endorsement of new models. This is particularly important for vehicles like the Volt that feature significant new technologies. Being named the North American Car of the Year will help convince customers that the Volt is truly a breakthrough vehicle, delivering the benefits of electric driving without the range anxiety associated with pure electric vehicles.” The all-new Chevrolet Volt features tracks produced at Faurecia’s San Luis Potosi, Mexico and Caligny, France sites. Truck of the Year GM Chief Technology Officer Tom Stephens poses with the Chevrolet Volt and its latest award as North American Car of the Year. Below are just some of the industry awards that the Volt has won since its launch, including Motor Trend Car of the Year, Green Car of the Year, and Automobile of the Year. The all-new 2011 Ford Explorer edged out finalists, including the Dodge Durango and Jeep Grand Cherokee, to be named North American Truck of the Year. “It’s a proud moment for Ford, our employees and our customers to have Explorer named North American Truck of the Year,” said Mark Fields, Ford President of The Americas. “Winning this honor for the third consecutive year confirms our One Ford plan is working to deliver vehicles people truly want and value, with industry-leading quality, fuel efficiency, safety and smart technology.” The Ford Explorer features exhaust system hot-ends and cold-ends produced at the Faurecia Dexter, Mo. and Gladstone (Columbus, Ind.) plants. In addition, recliners are supplied to the Explorer from the Bradford, Ontario and Caligny sites. Mark Fields, Ford President of The Americas, celebrates the win of the 2011 Ford Explorer as North American Truck of the Year during the Detroit auto show. Faurecia & NAIAS 2012 Volkswagen Passat VW finally named its new midsize sedan made especially for the North American market. It will feature Faurecia products supplied by the Chattanooga, Tenn.; Dexter, Mo.; Silao, Mexico; Louisville, Ky.; Cleveland, Miss.; San Luis Potosi, Mexico; Bradford, Ontario; Fountain Inn, S.C.; and Tuscaloosa, Ala. plants. 2012 Chevrolet Sonic The new sporty subcompact will replace the outgoing Aveo. The Sonic will feature products from the Silao and San Luis Potosi, Mexico plants. 2011 Chrysler 300 Chrysler’s large car was redesigned for the new model year. Faurecia’s Gladstone (Columbus, Ind.) and Taylor plants will produce content for it. Faurecia infos North America is a bimonthly newsletter published for Faurecia employees in the region. It provides and extends knowledge about the company, its people and activities. It delivers information about Faurecia’s processes, goals, performance and culture. January/February 2011. Copyright 2011. All rights reserved. Printed on recycled paper and uses soy-based, environmentally friendly ink. For questions, comments or article suggestions, please write to infosNA@faurecia.com. Editor-in-chief: Stacie Tong, Managing Editor: Christina Wootton, Contributing Editor: Marisa Fortuna
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