welcome to gkn- · pdf filechem-milling & aviation repair. mexicali low cost machining and...

Proprietary to GKN Aerospace Proprietary to GKN Aerospace

Welcome to GKN-ACS

Proprietary to GKN Aerospace Proprietary to GKN Aerospace 2


Business Portfolio & Focus in US

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ANA Headquarters TX

Mexicali Composites Low cost composite center

Alabama Integrated composite

structures & assemblies

Orangeburg - SC Aircraft subassembly

Advanced Composite Structures

St. Louis - MO Hard Metal Machining

High Speed AL Machining

Composite Structures

HLU/AFP

Aircraft Subassembly

Structures - CT RTM

Composites Development

Aerospace Structures

San Luis Potosi Low cost fan blade

machining & grinding

PreMac - KS Titanium machining &

aluminum wing skin technology leader

Aircraft Subassembly

Monitor - NY Titanium machining

technology leader

High Speed Aluminum Machining

Advanced Machine Structures

Bandy - CA Hinge center

Small Machined Ti and AL parts

ASTECH - CA Welded honeycomb

structures and fabrications

FAA-145 repair station

Chem-tronics - CA Leader in fan cases &

rings, engine structures

Chem-milling & aviation repair

Mexicali Low cost machining and

fabrication

Subassembly

Engine Products West

Muncie - IN Precision forgings

Cincinnati - OH Electro-chemical milling

of blades and vanes

Manchester - CT Precision machining of

fan blades and outer guide vanes

N. Charlestown - NH Precision machining of

fan blades and outer guide vanes

Engine Products East

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Composites at GKN Aerospace

Comprehensive Capabilities Design, Manufacture, Test and Certify

Full Range of Technologies and Materials Hand Lay-up Automated Tape Laying Fiber Placement Filament Winding RTM And RFI

Advanced Composite Manufacture and Bonding Complex Structure Assembly and Integration Turnkey Manufacturing Facilities Composite Research Centers

GEnx Composite Fan Case

737 Blended Winglet

A400M Composite Wing Spar

RTM – Fan Platform

Largest Composite Aerostructures Supplier in the World (non OEM)

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Composite Structures Manufacturing

Clean Rooms, Hand Layup, ATL, AFP

Pattern Cutting/Machining

Honeycomb Machining

Laser Ply Lay-up and Inspection

Bonded Composite/Metallic Assemblies

Autoclave and Oven Cure

Automated Drill and Trim

Inspection – Automated Ultrasonic Inspection System (AUIS)

Coordinate Measurement Machines

Fully Equipped M&P Laboratory

Fiber Placement Automated Drilling Center

Autoclaves NDI - AUIS

Complete Component Through Complex Assembly Fabrication Expertise

RTM

Auto Tape Layers Filament Winding Tape Winding

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Integrated Assembly

Manufacturing Work Cell Facility Layout

Lean Initiatives Applied to Each Program

Dedicated Customer Assembly Areas

Fully Integrated Products

Part-to-Part Assembly Philosophy

State of the Art Ergonomic Assembly Tooling Supporting Part-to-Part Process

Wing Trailing Edge Fan Cowl Door

Winglet

Engine Nacelle

Horizontal Stabilizer

787 Floor Assembly

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Strategic Outlook – GKN ACS

GKN ALABAMA Workforce of 1000 employees Key capabilities

Mid to Complex Composite Parts

Assembly structures with increased level of automation

Development of Out of Autoclave structures (Engine Components)

Develop Engineering Composite Technology Center (Panels, Engine Components, Rotorblades)

GKN SOUTH CAROLINA Workforce growth to 300 employees Key capabilities

Manual Assembly, minimum overhead

Large structures, equipment integration

Business Jet Fuselages, Wings

OEM Floors, Nacelles, Cockpits

GKN COMPOSITES MEXICALI Workforce growth to 200 employees Key capabilities

Hand Laminates

Carbon/Kevlar/Glass Fabric

Components delivery to GKN AL

Leader in Composite

Structures for the Aircraft and Engine Markets

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Health and Safety

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Continuous Improvement focused on Think Safe! Campaign

Significant improvements through the years

No Loss Time Accident for the past 3+ million production hours

TRR < 2.0, beating our target


Our ACS Safety Guidelines:

X

Eye and Footwear PPE

Gloves and Hearing PPE

Stop, Look, Listen

Use Pedestrian Doors

100% of Factory

As applicable in designated areas

100% of Factory

100% of Factory

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Alabama Leadership Team

VP and General Manager Daniele Cagnatel

Director of Quality Eric Baker

Director of Supply Chain Jay Woodrow

Director of Continuous Improvement

Rebecca Siers

Director of Finance Les Emanuel

GM Composite - Mexicali Loren Engel

Executive Assistant Donna Johnson

Director of Engineering Richie Hodges

Director of Human Resources Michelle Alcathie

Director of Manufacturing Rich Rogoski

Director of Bus. Dev. & IT Frank Greco

Director of Commercial Bus. Chelsea Mclaughlin

GM South Carolina Steve Pulliam

Director of Programs Tony Garnett

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GKN ACS Background

1985 – Tallassee, Alabama site established by Sikorsky Aircraft to manufacture composite details for the Blackhawk helicopter

1990 – United Technologies (Sikorsky and P&W) formed the Dow-UT joint venture with Dow Chemicals

1998 – Dow-UT acquired by GKN Aerospace

1999 – Montgomery site opened for transition of major assemblies from Sikorsky

2000-2002 – Business volume doubled by moving work from the UK (Airbus, MRAS) and adding to customer base (Lockheed Martin, GE)

2003 - 2006 – Continued to grow business through new GE/Boeing, Lockheed Martin, and Airbus programs together with new manufacturing technologies

2007 GKN invested with GE on the Gen-x first all composite case and formed

2008- Awarded Development program on Honda Jet

2009 – Relocated the Montgomery Assembly in the Tallassee expansion

2012 – Opened two new manufacturing facilities Mexicali & Orangeburg, SC

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Alabama Growth

500

Employees

$85

Million

2004

631

Employees

$127 Million

2005

761

Employees

$150 Million

2006

529 Employees

$68

Million

2003

Alabama Sales and Employment Growth

840

Employees

$170 Million

2007

877

Employees

$214 Million

2008

970 Employees

$228 Million

2009

980

Employees

$230 Million

2010

980 Employees

$250 Million

2011

960 Employees

$276 Million

2012

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Market Segments and Key Platforms for Growth

Composite Engine Components

GE 90 (B777)

GE CF6 (B767)

GE Genx-1B (B787)

P&W 4000/6000

Nacelle Cowlings

Blocker Doors

Composite Structure Components

Helicopter components and assemblies

Commercial Aircraft

Military Aircraft

Rotorblades

Integrated Assembly structures (equipped, heater elements etc.)

Assembly Structures Honda Fuselage

Honda Wings

Commercial Aircraft Assemblies

GKN ALABAMA / MEXICALI

GKN ALABAMA / MEXICALI

GKN ALABAMA / SC

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Customer Relationships

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Boeing Military Lockheed Martin Bell Helicopter Hondajet

Rolls Royce Boeing Commercial UTC Aerospace Systems

Key Strong Existing Relationships

Strategically Targeted

Airbus GE Aviation Pratt & Whitney Sikorsky

Strategic Objectives Expansion of content with key existing customers Capture content with targeted customers (Boeing, RR, Airbus, Bell) Improve customer balance to reduce market risk & increase growth potential on the Commercial Business (Rolls-Royce / Boeing)


Market Growth

GKN ACS is well positioned for growth

Composite aircraft structures is forecasted to grow at a CAGR of 11.2% from 2011-2021. High Volume Hand Lay-up supports low costs and completive advantage

Advance technology used for specific application only

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GKN ASC South Carolina

Strategic Objective: Locate low cost assembly site near key customers to off-load OEM scope & accelerate growth

Current Status 150,000 Sq. Ft. – New Facility – Production Ready

22 Acre site

Dedicated site for complex assembly

Facility production startup with Honeywell engine fan duct assembly Oct 2012

HondaJet Fuselage and subassemblies occupy ~25% of current facility

Qualification for CF6 Assemblies started with GE

GKN SC

Launch Team

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Product Sikorsky components successfully transferred

Qualification for GE: project plan in work, request for qualification initiated by end of Sept

GKN ACS Mexicali

Strategic Objectives Low Cost Competitive Enabler to GKN Aerospace North America

Offset Support to OEM’s Pursuit of Mexican Market

Capacity Enabler to Alabama / ANA Growth Strategy

Strategic Objectives

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GKN ACS - Alabama

~$280M 2012 sales

~1000 employees (non-union)

Total of 380,000 square feet of

manufacturing area

Land to expand ~325 acres

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ACS Core Competencies

Design and build small to medium complex composite assemblies

Primary structure hybrid assemblies

Composite fan case and acoustics assembly

Systems installation

Low cost US supplier for core competencies

Sikorsky UH-60 Blackhawk

Lockheed Martin F-22 Raptor

Airbus Jetliners

GEnx Engine

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Clean rooms/ hand lay-up with Laser Ply Projection (95th SF)

Gerber cutting systems (3) for composite materials Two Gerber tables 60 ft long

One Gerber table 45 ft long

Autoclaves (8 each, largest is 15’ X 50’)

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Manufacturing Facilities


Two CNC Honeycomb machining

GFM single cut tables

CNC machining of parts

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Quality Inspection Equipment 5-Axis Matec C-Scan Gantry System

Matec configured C-Scan 2-D Tank System

Meccasonics Submersion Ultrasonic Scan Tank

(4) Coordinate Measurement Machines

Fully Equipped M&P Laboratory Calibration Laboratory

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Quality Assurance

> Quality certifications/Approvals > ISO9001:2008 > AS9100-Rev. C > NADCAP - Composite & NDT > United Technologies ASQR-01 > Approved Supplier for Airbus, GE, Lockheed Martin > AS9102 - First Article Inspection (FAI) > Sikorsky Supplier Gold – “Awarded as Performing” > ISO14001:2004 > OHSAS 18001:2007

> Non Destructive Inspection > ASNT Level III Manager

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The Lean Enterprise Model

GKN Vision

(PE)

(PrE) (BPE)

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Common Language – With Focus Area’s

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Our Competence and Differentiator: Our People!

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Moving forward with the strategic agenda – GKN ACS

Sustain above market growth

Composite parts and structures in aircraft are forecasted to grow at CAGR 11.2% GKN ACS well positioned to capture the growth – cost competitive, motivated workforce

Operational excellence

Technology driving margin

Leverage global footprint

Lead in chosen markets

South Carolina facility for Large Assemblies Mexicali facility for low cost hand lay-up

Out of Autoclave technologies Flexible manufacturing systems

Lean Manufacturing system implemented as the operational model Increase Revenue stream by focussing on high volume and future growth platforms (787/NEO/737M)

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