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Pratt & Whitney AutoAirPratt & Whitney AutoAir
August 2010
This document is the property of United Technologies Corporation (UTC). You may not possess, use, copy or disclose this document or any information in it, for any purpose, includingwithout limitation to design, manufacture, or repair parts, or obtain FAA or other government approval to do so, without UTC's express written permission. Neither receipt norpossession of this document alone, from any source, constitutes such permission. Possession, use, copying or disclosure by anyone without UTC's express written permission is notauthorized and may result in criminal and/or civil liability.”WARNING -- This document contains technical data the export of which is or may be restricted by the Export Administration Act and the Export Administration Regulations (EAR), 15C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export, reexport, transfer or re-transfer of this technical data to any other company, entity, person, or destination,or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without prior written approval from P&W and authorization underapplicable export control laws.
EAR Export Classification: ECCN 9E991.
2
PWAA Organization
Operations Manager
Andy Storm
Sales
Claudia Carter
Quality Manager
Talha Rathur
Materials Manager
Jason Szalanski
ManufacturingEngineeringManager
Gary Franck
General Manager
Steve Foster
Human ResourcesManager
Michelle Blakely
Controller
Mike Friar
Customer ServiceManager
Jim McCoy
Thrust Reverser Team
Research &DevelopmentEngineeringManager
Gary Wigell
Customer Service
Rob Koresky
Leadership Team
Cell Leader
Don Reynolds
Cell Engineer
Colby Page
Quality Engineer
Don Reeves
Sales
Brian Garceau
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
3
Organization OverviewStatistics
Structure
4 Plants - 159,000 ft2
204 Employees – 65 Salary, 139 Hourly
ACE Site Silver
Plant 1
Plant 3
Plant 2
LansingCampus
SunfieldCampus
Plant 4
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
Incorporated in 1956
Acquired by Pratt & Whitney as part of theCADE Industries purchase in 1999
4 Divisions: OEM, MRO, Thrust Reversers &Ground Test Nacelles
PWC19.3%
OEMROOEM Capability MRO Flexibility
For the life of your engine
TM
OEMROOEM Capability MRO Flexibility
For the life of your engine
TM
44
Composite Product Divisions
• Driven by repair development
• Positioned around EC network
• Leader in A330-300 (PW4168) repairs
• Targeted growth in V2500 market
• Focused on UTC subsidiaries• ROS threshold drives OEM strategy
• Industry leader in quality & durability
• Supplier to all major engine OEMs
RepairDesign Build Spares RDE
OEM
MRO
TR
TEST
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
5
CUSTOMERSCUSTOMERS
EMPLOYEESEMPLOYEES
QUALITYQUALITY
Technology & InnovationDelightDelight
CustomersCustomers
FINANCIALFINANCIAL
P&W AutoAir - 2010 Roadmap
Preserve the Core and Stimulate GrowthPreserve the Core and Stimulate Growth
Unm
atchedEH&SPerformance
HighestB
usinessEthics
Always
Perfect Quality Wins Customer Loyalty
Customer Scorecard > 6.0; Provider of Choice
Employee Engagement over 65% survey favorability
ACE Gold & Supplier Gold value streams drive perfect Quality
Deliver financial plan commitments
EH&S• Achieve EH&S plan• Energize People Based Safety (PBS) programEmployee• Acquire, develop & retain talent to grow AutoAir• Drive integrity and meet all UTC ethics compliance goals• Execute key employee communications• Implement a sustainable training program for salary and hourlyFinance
• Execute a robust Manufacturing Engineering and Operations processreview strategy to expand margins and drive quality targets
• Implement cell productivity measures with 10% improvement• Explore global outsourcing of SAP report generation and delivery
• Develop creative solutions and cost reduction initiatives to competemore effectively on A330 Thrust Reverser campaigns
Customer• Continue > 95% OTD performance• Achieve consistent TR TAT of 60 days
• Successfully complete Test Nacelle design and First Engine To Test(FETT) for PW1217Gand PW1524G programs
• Develop and implement a One Company OEMRO strategy for theNGPF program
• Grow OEMRO market share and expand field service offerings tosupport 2012 and beyond
• Implement OneAero customer service platform• Establish a world class Composite Incubator to drive 2X growthQuality
• Achieve ACE Site Gold through robust tool usage and metricsmanagement
• Develop and certify a robust quality clinic process
66
Control Tower
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
7
Customer & Sales Overview
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
ASIA-PACIFICEagle Services Asia (13%)
Thai Airways (8%)
Malaysia Airlines (3%)
Korean Airlines (1%)
China Airlines (TEST & MRO) (1%)
GE Malaysia (1%)
Christchurch (1%)
Japan Airlines (1%)
TAM (14%)
P&W - Canada (11%)
P&W/PDC (10%)
PWEH GTF (9%)
GP&W Cheshire (5%)
CEC (TEST & MRO (3%)
Standard Aero (3%)
United Airlines (2.5%)
EUROPE/M.E.Lufthansa (1%)
Rolls-Royce (1%)
HiFly (1%)
LTU (Air Berlin) (1%)
H+S Aviation (1%)
Americas
68%
Europe
4%
Asia
28%
Region YTD June 2010 Sales
Test
22%OEM
19%
MRO Core
26%Thrust Reversers
33%
Product YTD June 2010 Sales
THE AMERICAS
87 Total CustomersTest
13%OEM
31%
MRO Core
36%Thrust Reversers
20%
Product 2009 Sales
Americas
68% Europe
7%
Asia
25%
Region 2009 Sales
88
Quality
COPQ: .43% YTD (Jan to July)
Escapes: 3 YTD (0 for United)
Audits: CASE, No majors.
Certified: AS9100FAA FAR-145EASACAAC CCAR-145 R3CAAVTHAILAND DCA
9
Fan Blade Fairing Journey Results
10
PW2000 Case Kaizen Event
KaizenNewspaper
Products
Optimize the OEM productionand MRO repair of the Cases,Liners and Fairing product linesto increase productivity, improveEH&S and reduce cost of poorquality.
Mission Statement
Current State
Cell Layout
Paper Doll Model
Blue Book Standard Work
Reduction of600 sq ft
11
Recv &Uncreated
-Hoist-Tools
InnerInsp area
(Part on Fixture)
OuterInsp area
(Part on Fixture)
Insp & DispositionDesk/Computer
DisassembleArea
-Fixtures-Drills-Tools
-Work bench
OutflowtoClean
Scheduleboard
Box forShipping
-Hoist-Tools
Start
Finish
OutflowtoSub
contract
Scheduleboard
Recv &Uncrate
-Hoist-Tools
InnerInsp area
(Part on Fixture)
OuterInsp area
(Part on Fixture)
Insp of Sub contractDesk/Computer
AssembleArea
-Fixtures-Drills-Tools
-Work bench-Hoist
Final Insp &8130
Final InspDesk/Computer
Create &Ship
-Hoist-Tools
Future Nozzle Cell
10’ X 10’ 3’ X 10’
Old Cell Layout
New Cell Layout
• Cell Layout•Problem No cell layout•Solution Developed cell LayoutImplementing in 3Q 2010
•Old Nozzle Cart•Problem Hard to move parts•Carpet got Dirty•Solution Had vendor developa cart that is easy to moveand stays clean
•Rivet removal•Problem Hand drilling notrepeatable•Solution Controlled Feeddrilling process implementingin Q3 2010
Old Nozzle Cart
New Nozzle CartNew Controlled Drilling
Process
1212
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
13
Composite Product Grouping
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
14
Composites Incubator – The Genesis
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
ProcessVillage
CellularManufacturing
DevelopmentCell
• Developmentperformed inmanufacturingcell
• Developmentwork done byManufacturingEngineer
• Product movedfrom process toprocess
• Developmentperformed inmanufacturingcell impactedOTD and TAT ofproduction parts
• ManufacturingEngineersfocused on cellefficiencies
• Developmentefforts wereconsidered adistraction by cell
• Developmentcell dedicated tonew product &process created
• DedicatedDevelopmentEngineers
• DedicatedSkilled Hourlyteam
• Space createdby Kaizen events
• FlexibleDevelopment celllayout
• Developmentwork done inconjunction withtarget cell
• Developmentwork done withP&W UnitEngineering onsite
2000 2005 2010 Future
15
Product Life Cycle & EngineeringDesign &
Development Manufacturing SparesSupport
RepairDevelopment Repair
OEM
MRO
Test
• Already contracted for $8.5M in Customers Paid NRE For BA “C” Series AndMRJ Test and FTB Nacelle System Development
• Over 100 Composite Repairs developed annually
• Working With CSMC on BA “C” Series And MRJ OEM Component Development
• Use Of OEM Development Work To Develop Repairs For BA “C” Series AndMRJ Engine Components
COMPOSITES INCUBATORDEVELOPMENT RECIPIENTS
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
1616
Composites Incubator – Flexible Manufacturing Cell
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
• Staffed with Senior Engineers and Skilled Hourly Employees (Article 17.7 of IAM Contract)• Dedicated to Developing Product And Processes• No Production Interruptions or Resource Competition• Full Array Of Movable Work Stations, Clean Room, Etc.• Overhead Carry System For Power, Air and Vacuum Drops• 1850 Square Feet of Manufacturing Area• 5-Axis Machine Center, 5’x7’ Clave in cell
1717
31
V2500 Panel Repair
Cost
Sales
REATech Data
Year5 Total
Part Number(s)
Customer(s)
Target Price
Volume
Year4
Target DateTarget Cell
MarginATA
Year3
Year2
Year1
PWAA
Rev.Engr.Comp.
Sales
MarketPlanComp.
PWAA
Router& BOMComp.
PWAA
Tooling&
FixtureAvail.
RSA
RSAComp.
Start
Name
Due
End
PWAARSAGSEPWAALegalPWAAPWAAPWAASalesGroup
1st PartComp.
RSAProg.Plan
TechDataAvail.
DesignReview(R3)Comp.
LegalReviewComp.
HeadsAvail.
AssetAvail.
ProjectLaunch(R2)Comp.
NeedID’dMilestone
Priority: 2OEM MRO TR’s Test Unit Funded Capital FundedGSE Funded
38
V2500 Splitter Repair
Cost
Sales
REATech Data
Year5 Total
Part Number(s)
Customer(s)
Target Price
Volume
Year4
Target DateTarget Cell
MarginATA
Year3
Year2
Year1
PWAA
Rev.Engr.Comp.
Sales
MarketPlanComp.
PWAA
Router& BOMComp.
PWAA
Tooling&
FixtureAvail.
RSA
RSAComp.
Start
Name
Due
End
PWAARSAGSEPWAALegalPWAAPWAAPWAASalesGroup
1st PartComp.
RSAProg.Plan
TechDataAvail.
DesignReview(R3)Comp.
LegalReviewComp.
HeadsAvail.
AssetAvail.
ProjectLaunch(R2)Comp.
NeedID’dMilestone
Priority: 3OEM MRO TR’s Test Unit Funded Capital FundedGSE Funded
Composites Incubator – V2500 Engine MRO
Project TaskApproval R2 Dev
HardwareScan &Model
PanelData Tol Study REDA
ApproveBushingData Tol Study REDA
Approve Matl Anal SampleTool
PartSample Part Test DDM
Create Structures ASR PatentSearch R3 EA
Approve RSA Part Tool Ops Shts RQR R4
A/O Panel 5/9/08 8/25/09 8/26/09 10/6/10 5/4/10 3/1/10 7/30/10 7/23/10 7/30/10 8/16/10 3/10/10 9/8/10 9/23/10 10/7/10 10/21/10 10/21/10 11/4/10 11/24/10 12/1/10 12/8/10 12/17/10 11/5/10 12/20/10 1/31/11 2/14/11Seal 10/10/08 12/15/08 1/12/09 N/A 5/6/09 5/22/09 6/5/09 N/A N/A 6/9/09 7/9/09 9/7/09 9/9/09 10/10/09 12/15/09 1/30/10 N/A 2/9/10 1/30/10 2/10/10 8/27/10 N/A 8/6/10 8/27/10 9/1/10Splitter 5/6/10 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 5/18/10 5/26/10 N/A N/A N/A 5/28/10 N/A 6/5/10 6/21/10 N/A N/A
32
V2500 Seal Repair
Cost
Sales
REATech Data
Year5 Total
Part Number(s)
Customer(s)
Target Price
Volume
Year4
Target DateTarget Cell
MarginATA
Year3
Year2
Year1
PWAA
Rev.Engr.Comp.
Sales
MarketPlanComp.
PWAA
Router& BOMComp.
PWAA
Tooling&
FixtureAvail.
RSA
RSAComp.
Start
Name
Due
End
PWAARSAGSEPWAALegalPWAAPWAAPWAASalesGroup
1st PartComp.
RSAProg.Plan
TechDataAvail.
DesignReview(R3)Comp.
LegalReviewComp.
HeadsAvail.
AssetAvail.
ProjectLaunch(R2)Comp.
NeedID’dMilestone
Priority: 3OEM MRO TR’s Test Unit Funded Capital FundedGSE Funded
• Seal Repair For CEC/UAL to be ready on September 1st , Hundreds of parts ready to induct
• A/O Panel scheduled to be repair ready in February 2011, working with GSE to pull back into 2010
• Splitter Repair complete
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
1818
30
GTF Fan Blade
Cost
Sales
REATech Data
Year5 Total
Part Number(s)
Customer(s)
Target Price
Volume
Year4
Target DateTarget Cell
MarginATA
Year3
Year2
Year1
PWAA
Rev.Engr.Comp.
Sales
MarketPlanComp.
PWAA
Router& BOMComp.
PWAA
Tooling&
FixtureAvail.
RSA
RSAComp.
Start
Name
Due
End
PWAARSAGSEPWAALegalPWAAPWAAPWAASalesGroup
1st PartComp.
RSAProg.Plan
TechDataAvail.
DesignReview(R3)Comp.
LegalReviewComp.
HeadsAvail.
AssetAvail.
ProjectLaunch(R2)Comp.
NeedID’dMilestone
Priority: 1OEM MRO TR’s Test Unit Funded Capital FundedGSE Funded
34
GTF Fan Case Liners and Bond
Cost
Sales
REATech Data
Year5 Total
Part Number(s)
Customer(s)
Target Price
Volume
Year4
Target DateTarget Cell
MarginATA
Year3
Year2
Year1
PWAA
Rev.Engr.Comp.
Sales
MarketPlanComp.
PWAA
Router& BOMComp.
PWAA
Tooling&
FixtureAvail.
RSA
RSAComp.
Start
Name
Due
End
PWAARSAGSEPWAALegalPWAAPWAAPWAASalesGroup
1st PartComp.
RSAProg.Plan
TechDataAvail.
DesignReview(R3)Comp.
LegalReviewComp.
HeadsAvail.
AssetAvail.
ProjectLaunch(R2)Comp.
NeedID’dMilestone
Priority: 4OEM MRO TR’s Test Unit Funded Capital FundedGSE Funded
Fwd Liner
Ice Liner
Rubstrips
Aft Liner
Case Bont
Composites Incubator – GTF OEM / MRO
• 18 blades per engine set, 340 engines per year, 6000+ blades Per year, 20 year product cycle
• Guaranteed MRO work, Leading edge, Erosion Coating and Wear Pads (GE90 Fan Blade Model)
• Tech Data from OEM manufacturing and capital equipment will be key barriers to entry into the MRO market
Project Need ID'dProjectLaunch
HeadsAvail Eng. Req.
DesignReviewComp.
Tooling &FixtureAvail.
Router /BOMComp.
First partComp.
FirstArticleInsp.
GTF Fan Blade 2009 Jan-10 Feb-10 Mar-10 Mar-10 Jun-10 Feb-10 Feb-10 Feb-10GTF Fan Case 2009 Feb-10 Mar-10 Mar-10 Jun-10 Jul-10 Jul-10 Aug-10 Aug-10GTF FWD Liner 2009 Feb-10 Mar-10 Mar-10 Jun-10 Jul-10 Jul-10 Aug-10 Aug-10GTF AFT Liner 2009 Jan-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10GTF Ice Liner 2009 Jan-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
1919
Composites Incubator – V2500 Thrust Reverser
Project TaskApproval R2 Dev
HardwareScan &Model
SurfaceData
InterfaceData
REDAApprove Matl Anal Sample
ToolPart
Sample Part Test DDMCreate Structures ASR Patent
Search R3 EAApprove RSA Part Tool Ops Shts RQR R4
V2500-A5 T/R 5/5/10 9/15/10 6/25/10 9/1/10 10/1/10 10/1/10 10/21/10 9/15/10 9/30/10 10/15/10 10/30/10 11/7/10 12/15/10 12/31/10 N/A 1/7/11 1/15/11 1/30/11 1/30/11 1/15/11 2/15/11 2/30/11
• Acquired Left Hand Door, still needs to have Overhaul tag before Reverse Engineering can begin per RESW
• Right Hand Door due in at the end of August, Structural Repairs are consistent door to door
• Pushing to spend the $800k tooling budget in 2010
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
20
REPAIR DEVELOPMENT
MATERIALS RESEARCH AND DEVELOPMENT
COMPOSITE LAMINATE AND HYBRID METAL-COMPOSITEDESIGN
RE-DESIGN OF METALLIC COMPONENTS INTO COMPOSITES
STATIC AND DYNAMIC STRUCTURAL ANALYSIS
FINITE ELEMENT ANALYSIS
MODAL & FREQUENCY
LAMINATE ANALYSIS
PROTOTYPE DEVELOPMENT
FAILURE ANALYSIS & DISTRESS MODE STUDIES
ACOUSTIC DESIGN AND EVALUATION
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
20
Engineering Capabilities
21
CAD•CATIA
•PRO/ENGINEER
•UNIGRAPHICS
•AUTOCAD
CAM•PRO/MANUFACTURE
•SMARTCAM
•ICAM
CAE•COSMOS/M
•MECHANICA
•MSC NASTRAN
•GEOMAGIC
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
21
Computational Capability
22
FROM EXISTING PART TO DIGITAL SURFACEPratt & Whitney AutoAir has both LASER and probe digitizing capabilitythat allows the product definition to be captured as a digital surface. Thesoftware can analyze the data from multiple parts and determine anominal dimension and a tolerance band on features for future repairs.
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
22
Reverse Engineering
23
FINITE ELEMENT ANALYSISStatic and dynamic analysis is performed on structures in the “as designed” state and “as repaired”state. The results are compared to show compliance with the applicable FAR’s. The part metrology,material and construction are determined by reverse engineering.
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
23
Composites Structures Validation
24
VALIDATION &VERIFICATION
Unit 905
45.97104
212.2911
126.1052
0
20
40
60
80
100
120
140
0 50 100 150 200 250 300 350
Frequency (Hz)
G(peak)
0
20
40
60
80
100
120
140
G(peak)
Accelerometer 1Accelerometer 2Accelerometer 3Controller feedback
VIBRATION OR MODAL TESTINGVibration testing is the process of applying a controlled amount of vibration to a structure to determinethe frequency response function and/or modal characteristics. Vibratory input is provided by meansof an electro-dynamic shaker mechanism capable of producing a forcing function sufficient to excitethe normal modes of the structure.
A nacelle assembly has specific frequency characteristics that relate directly to the stiffness / massrelation and connectivity of the structure. This technique makes it possible to compare and verify arepaired nacelle assembly with the systems specific frequency characteristics.
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
24
Composites Structures Verification
25
Non-Destructive Evaluation With Laser Shearography• Determines Size and Location of Disbonds in Honeycomb Sandwich Panels• Determines Size and Location of Delamination in Laminated Structures• Determines Size, Location & Number of Inclusions in Molded Panels & Laminates• Updated high resolution equipment on order and due in house on October 15th, 2010
NDI of Fan Case Abradable Laser Unit in Vacuum Chamber
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
25
Laser Shearography
26
Rayl Testing Device (Raylometer) for Measuringthe Pressure Drop Across an Acoustic Face
Zonic AIMSIII Testing Device for DeterminingAcoustic Impedance and Reactance.
“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”
26
Acoustic Evaluation
27
ACE Journey to SILVERSILVER
• First Units Transferred from HAC• Originally Located in Plant 2• Transactional Customers• Minimal WIP and Capacity• 400+ Day TAT
• Transferred to Plant 3• Established Contractual LTA’s with Customers• Maximized Capacity to 48 Units per Shift• 100+ Day TAT
2015
• ACE Silver• TRx Standard Work• Gated Flow
• Future Plant Layout• Plt.1&3 Consolidation
Qualifying
2004
2007
2008
2009
Bronze
Silver
Gold
Qualifying
2009
2010
Bronze
Silver
Gold
•Test 6S – Silver
2000
28
Before ACE
2929
Thrust Reverser 2010 YTD Performance
30
PWC19.3%
OEMROOEM Capability MRO Flexibility
For the life of your engine
TM