FES

FES

1

Aircraft AvionicsSpace Flight Electronics

Midwest City

26 Years of Customer-Focused Excellence

in Electronics Engineering Design and Manufacturing

High Reliability Manufacturing

Automated Test /SimulationSystems

Maritime Radar and Video Distribution Systems

September 2007

FES

StillwaterISO 9001:2000

Certified

AS 9100 Certified

Northrop Grumman World Class Team

Awards-2002, 2003 & 2005

Boeing Supplier of the Year Awards—

2001 & 2005

Chuck GrayVice President & COO chuckg@fescorp.com

NGST: GOLD Supplier

Boeing GOLD Supplier

86,500 Sq Ft Facility

FES

FES

2

Customer Satisfaction

– On time delivery/Product Acceptance:100%

– Boeing & Northrop Grumman Gold Suppliers 2005

– Boeing Diversity Supplier of the Year: 2005

– NGST Gold Supplier 2006

Revenue per Employee

Our Customers Our PeopleInternational

2%

Others5%

Northrop Grumman

6%

NAVSEA35%

Boeing52%

FY06 Revenue: $18.1M

D&B Rating: 4A1 Total Team

Strength: 90

FY 06 Business Performance

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

200,000

Revenue Per Employee

2002

1998

2006

FES

FES

Customer Focused Engineering Expertise

Subsystems/Product/Systems Engineering• Systems analysis• Reverse engineering• Systems engineering• Systems integration• Electronic/electrical design• Mechanical design• Software development/ documentation• Systems testing• Mil-spec drawings/technical documentation and training manuals• Configuration management• Technology innovation and product enhancement

KickoffM eeting

Analys is :Reliability,

P roducability,M aintainability,

Availability

Parts andEquipm entSelection

SystemR equirem ents

R eview

Pre lim inaryH ardw are

D esign

Pre lim inarySoftw areD esign

Pre lim inaryD esign R eview

C ritica l D es ignR eview

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M anufacturing

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In tegra tion

In form alFunctiona lVerifica tion

T esting

T estR eadiness

R eview

Phys ica lC onfigura tion

Audit

D es ignQ ualifica tion

T esting

Functiona lC onfigura tion

Audit

Equ ipm entM anufacturing(P roduction)

AcceptanceT esting

Packag ing andShipm ent

H /W & S /WR equirem ent

Analys is

Transition toProductionP lanning

Produc ib ility In tegra tion

M anufacturingR eadiness

R eview

Drawing Release

Part P rocurem ent(Production)

ContractAw ard

PeerR eviews

PeerR eviews

LessonsLearnedC apture /

App lica tion

P roductionR elease

D raw ings/AT P

F irs t A rtic leBuild /

Q ualifica tion

In tegra te LessonsLearned in to M FG

Processes

Tomorrow

Yesterday Today

FES

FES

Flexible, Customer-Focused Manufacturing

PCB Automated Assembly AreaSpace Manufacturing

Soldering

• Assemble and inspect to NASA 8739.3

• Also perform to the requirements of ANSI-JSTD-001C

• 4000 sq.ft. clean room, controlled access, temperature, and humidity with N2 dry box storage

• Class 1A ESD Controls

• Component lead-forming for space applications

• Gross/Fine Leak Test

• Coating and staking of PWB’s and assemblies per NASA 8739.1

• Foaming of completed assemblies is performed to internally developed processes, approved by customer

Cable and Harness Assemblies

Specifications

• JSTD-001C, Class 3

• NASA 8739.4

Cable Types• Branched wiring

harnesses

• Ribbon Cables

• Triax

• Coax

• Multi-Conductor shielded

• Environmental back shells

• Point-to-Point wire routing

• Interconnect cables for racks

Assembly/Test Techniques

• Conductive Potting

• Non-Conductive Potting

• Sleeving & Heat Shrink

• Crimp & solder cup connections

• Continuity testing

• Insulation Resistance, 1500 VDC Limit

• Dielectric Breakdown, 1000 VAC Limit

• Gas-Tight Testing

• No limitation on number of wires

• Connector Type: No limitation with proper crimp tool

Assembly / Wiring

• Cable and wire harness assembly for both systems and test equipment

• Broad spectrum of assembly and wiring capabilities, including high-density wire-wrap and cables

• Assembly of system racks, including electronic drawers, interconnect panels and cabling

• Top level racks pass shock and environmental qualification testing

• Wire-wrap assembly for F-18 Stores Management -- over 1150 units delivered, 100% on-time

• MIL-STD-1130B

• Qualified to ANSI-JSTD-001C and NASA 8739.2• Inspection Capability includes 35º variable plane x-ray for BGA• Capacity--prototype qualification to 250 boards/day• Ball Grid Array Fine pitched parts placement

FES

FES

Product Test, Documentation and Packaging

• Automated testing of slices and units utilizing the Common Core Test Set

• Functional, thermal and vibration testing to meet customer requirements

• Vibration testing Ling 612vH in 3 axes, both random and sinusoidal, for qualification and acceptance testing

•Thermotron SE-600, Ecosphere EC 312, and Tenny Ten thermal chambers

•BEMCO Model AGH Thermal Vacuum Test Chamber

• End Item Data Package• Certification of Compliance• As-shipped configuration lists• As-built materials lists• Test Reports• Test Data• Trend Data• Discrepancy Documents• Photographic/X Ray Records• Prohibited materials Verifications• Quality Verification Documents

Documentation

Aerospace Testing Test & Inspection of Cables/Harness

• DIT-MCO, Model 2115• Applications: Test & inspection of aircraft,

telecom & computer cable assemblies including twisted-pair leads & shields

• Capacity: 2200 test points (1100 input/output) • Expandable for additional test points• Onboard Operator Interface w/display

(stowable)• Onboard Printing • Standard Sub-D Interface• Smart Probe Equipped• 1500 VDC Isolation Testing• 1000 VAC Breakdown Testing• Continuity/Discontinuity Testing• 4 Wire Continuity Testing/DC Hipot Testing

FES

FESFES Intern Program

• FES is committed to a long-standing program for developing engineering internsin the State of Oklahoma

– FES has hosted 18 Interns over the past 9 years, including 8 NASA Space Grant Interns over the past 5 years.

– All interns enhanced their prospects for future employment based on experience gained at FES

– 6 interns accepted full-time positions at FES after completing college degrees

– Others used experience to find employment opportunities elsewhere in the high-tech industry. Several are still providing economic benefit within the State of Oklahoma

– FES has, and continues to directly benefit from the ‘fresh’ technical insight, enthusiasm and quest for practical knowledge that each intern has brought to FES

FES

FES

NASA Space Grant and Fellowship Program

• Summer 2003, NASA Oklahoma Space Grant Consortium (OSGC) sponsored Ryan Mounts, OSU MSEE graduate student as an Intern at FES

• Ryan worked in FES Naval Systems Group on a design team developing a next generation, advanced sensor distribution system for US Navy Aegis-class Cruisers

• Ryan graduated with an MSEE in Dec 2003 and accepted a job with METI at the Mike Monroney FAA Center in OKC.

Intern quote “My experience as a NASA Intern has been productive and informative. The internship helps to fill gaps left by the limited hands-on application in the classroom.”

FES

FES

NASA Space Grant and Fellowship Program (continued)

• Summer → Fall 2004, NASA Oklahoma Space Grant Consortium (OSGC) sponsored two students as Interns at FES

• The first intern, Aleia Vest, BSIE student at OSU, worked in FES Manufacturing Group on two projects: 1) Develop Process to improve tracking of material 2) Develop plan to upgrade automated circuit card assembly area to clean-room environment

• Aleia graduated with a BSIE in December 2004, and accepted a job with the Industrial Engineering Department in OKC.

Intern quote “My time at Frontier greatly prepared me for the job at UPS and helped me determine the career direction I want to pursue. I also plan to continue my education toward an MBA degree soon.”

FES

FES

NASA Space Grant and Fellowship Program (continued)

• Summer → Fall 2004, NASA Oklahoma Space Grant Consortium (OSGC) sponsored two students as Interns at FES

• The Second intern, Todd Parnian, MSEE student at OSU, worked in FES Aerospace Group on design, development, fabrication, assembly, and integration of a new test system for the Engine Fuel Display.

• Following summer/fall internship and graduation with MSEE in December 2004, Todd joined FES as a full time Hardware Engineer working on a complex engineering redesign project for the T-43 aircraft.

Intern quote “The knowledge gained during the internship has given me the confidence and critical thinking skills beyond what I gained in the educational institution alone.”

FES

FES

NASA Space Grant and Fellowship Program (continued)

• Summer 2005, NASA Oklahoma Space Grant Consortium (OSGC) sponsored two students as Interns at FES

• The first intern, Joy MacDonald, BSBA student at OSU, worked in the FES Accounting Department contributing to the preparation of the FES FY2006 Operating Plan and assisting with Accounts Payable and Payroll functions.

• Joy continued to work part time at FES while pursuing a Masters degree in Business Administration.

Intern quote “My eyes have been opened to the world outside the classroom… Everyone should have the opportunity I was given. I feel an education is not fully complete without an experience like this.”

FES

FES

NASA Space Grant and Fellowship Program (continued)

• Summer 2005, NASA Oklahoma Space Grant Consortium (OSGC) sponsored two students as Interns at FES

• The Second intern, Ross Haimson, BSEE student at OSU, worked in the FES Aerospace Group developing two thermal monitoring test stations to support NASA space flight satellite programs.

• Ross graduated with BSEE in December 2005, and accepted a job with General Dynamics Satcom Technology in the Dallas area.

Intern quote “[The internship] was a very positive experience for me. I have grown both technically and professionally. I will undoubtedly use the skills gained here throughout my career.”

ARE Filter Slice

HDE Slice

FES

FES

NASA Space Grant and Fellowship Program (continued)

• Summer 2006, NASA Oklahoma Space Grant Consortium (OSGC) sponsored one student as an Intern at FES

• John Miller, an engineering student from OU, worked in the FES Aerospace Group on the design of interface cables and test software for continuity, insulation resistance, and hi-pot testing of production wire harnesses. Intern was also trained in OSU’s Scanning Electron Microscope Energy Dispersive Spectroscopy lab on the application of prohibited materials testing.

• Following summer internship, John worked in a student co-op program at Hewlett-Packard in the Dallas area. He is now full-time student at University of Oklahoma with plans to graduate in December 2008.

Intern quote “Being involved in the entire process from design to testing afforded me the opportunity to gain technical knowledge while also learning a lot about how things are done in a corporate setting.”

FES

FES

NASA Space Grant and Fellowship Program (continued)

• Summer 2007, NASA Oklahoma Space Grant Consortium (OSGC) sponsored two students as Interns at FES

• The first intern, Daniel James, BSMIS student at OUworked in the FES Information Systems Group supporting computer and communications infrastructure of the company, performing a company-wide transition to Microsoft Office 2007, and writing macros to convert data to a new Enterprise Resource Planning system.

• Following summer internship, Daniel returned to school at the University of Oklahoma where he plans to graduate with a BSMIS degree in May 2008.

Intern quote “I was able to gain valuable work experience and knowledge. My experience was very fulfilling and worthwhile.”

FES

FES

NASA Space Grant and Fellowship Program (continued)

• Summer 2007, NASA Oklahoma Space Grant Consortium (OSGC) sponsored two students as Interns at FES

• Second intern , Kurt McLain, BSMET student at OSU, worked in the FES Aerospace Group, where he designed, developed, and fabricated assembly fixtures for building and testing aerospace wire harnesses. Kurt also performed testing of wire harnesses and circuit card assemblies for high reliability production ground support equipment.

• Following summer internship, Kurt is continuing to work part time at FES while working to complete a BSMET degree in May 2008.

Intern quote “I have gained technical and professional skills which I would never have learned in the classroom setting. These skills will continue to be useful throughout my professional career.”

FES

FES

NASA Space Grant Internship Participants at FES

InternName

InternshipPeriod

FES Group

ProjectIntern Degree

School Intern Status

Ryan Mounts

Summer 2003

Naval Advanced Sensor Distribution System Design MSEE OSUJob at METI – Mike Monroney FAA Center in OKC

Aleia VestSummer

2004Mfg Kit Cart Design & Upgrade SMT Area BSIE OSU

Job at UPS Industrial Engineering Dept in OKC.

Todd Parnian

Summer-Fall 2004

Aero EFD Test Set Design MSEE OSUJob at FES in Test and Measurement Systems.

Joy MacDonald

Summer 2005

AcctgFY2006 Operating Plan; Payroll; Accounts Payable

BSBA OSUWorked part time at FES while pursuing MBA.

Ross Haimson

Summer 2005

AeroDeveloped Thermal Monitoring Test Stations for NASA space flight satellite programs

BSEE OSUJob with General Dynamics Satcom Technology in Dallas area.

John C. Miller

Summer 2006

AeroDesign of interface cables and software for testing production wire harnesses

BSEE OU

Worked in student co-op program at Hewlett-Packard in Dallas area. Now full-time student at University of Oklahoma with plans to graduate in December 2008.

Daniel JamesSummer

2007ISG

Support computer and communications infrastructure for company

BSMIS OUFull time student at University of Oklahoma with plans to graduate in May 2008.

Kurt McLainSummer

2007Aero

Design of interface cables and software for testing production wire harnesses. Design & Fab assembly fixture. Test production wire harnesses and circuit card assemblies

BSMET OSU

Working part time at FES while completing BSMET degree at Oklahoma State University. Plans to graduate in May 2008.

FES

FES

NASA Space Grant Program Summary

– The NASA Space Grant Program has provided a significant benefit to FES and its technology pursuits

– The program is important for the government, for the industrial base, and for technology development and education of tomorrow’s Aerospace Technical and Management leadership

– FES is committed to continued support, development and advocacy of the program

FES

FES