aero structure
TRANSCRIPT
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Kongsberg Gruppen ASA ( KONGSBERG) is an internationaltechnology corporation that delivers advanced and reliablesolutions that improve safety security and performance incomplex operations and during extreme conditions
KONGSBERG is a customer focused organization with aworldwide performance culture KONGSBERG workswith demanding customers in the global defencemaritime oil and gas and aerospace industries
WORLD CLASS- through people technology and dedication
C O N T E N T SK O N G S B E R G A E R O S T R U C T U R E S
AE R O S T R U C T U R E SCenter of Excel lence - Composites and Al loys
K O NG S B E R G V AL U E S
AE R O S P AC E amp D E FE NC E
I ND U S T R Y 983085FI R S T C AP AB I L I T I E S
B R E AK T HR O U G H MI S S I L E T E C HNO L O G Y
O FFS HO R E AND S U B S E A
P RO DUCT I O N
NE W MO D E R N FAC I L I T YBui lt to support F-35 ful l - rate production
S T R AT E G I C FO C U S
E N G I N E E R I N G
E NG I NE E R I NGWorld-class expert ise
ST EP BY ST EP
C O MP O S I T E S
AD V ANC E D ME C HANI C AL MANU FAC T U R I NG
R E P AI R AND O V E R HAU L O F R O T O R C R AFTT O TAL Q UALI T Y MA N AGEMEN T
S T AT E 983085O F983085T HE 983085AR T MANU FAC T U R I NG
ME T R I C AND P E R FO R MANC E 983085B AS E D C U L T U R E
C O MP E T E NT MANAG E R S P R O G R AM983085 AND P R O D U C T I O N T E AMS
B U S I NE S S C O ND U C T
WHAT WE START WE FINISH WE DO NOT GIVE IN
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KONGSBERG creates and delivers high-technologicalsolutions to people operating under challenging conditionson the oceans in the deep sea in defence and in space KONGSBERG har facilities world-wide with over 7000employees working in more then 25 countries aroundthe world The Grouprsquos most important markets are EuropeUSA the Middle East and Asia with main focus on offshoremerchant marine and defence
KONGSBERG Defence Systems (KDS) is one of 4 strategicbusiness units in KONGSBERG KDS is Norwayrsquos leadingand major international supplier of defence and aerospacesystems and delivers products and systems for commandand control weapons guidance and sur veillance communi-cations and missiles KDS produces also advanced compositesand engineering products
KONGSBERG Aerostructures is one of six divisions underKDS with key focus on complex composites and high-alloymetal structures
KONGSBERG GROUPKONGSBERG AEROSTRUCTURES983085 CENTER OF EXCELLENCE FORCOMPOSITES AND ALLOYSA TOTAL OF 30000 SQUAREMETERS PRODUCTION AREA
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KONGSBERGAEROSTRUCTURES983085 CENTER OF EXCELLENCE 983085 COMPOSIT ES AND ALLOYS
KONGSBERG Aerostructures is a leading internationalsupplier of complex sub-assemblies to large international
manufacturers in the global aerospace and defence industryThe division also supplies the offshore and subsea market
with key structural elements and has through many yearsoffered overhaul of military rotorcraft
CO MP LEX SYSTEMS F O R EXTR EME USEKONGSBERG Aerostructures is Center of Excellence for complex composite
structures and metallic alloy assemblies and details for systems ope ratingunder extreme loads and conditions Our core capabilities ranges from
design prototyping and industrialization to large volume manufacturingfor Aerospace and other high performing markets
We offer leading manufacturing- and engineering expertise in material andprocessing technology specializing in carbon fiber composites and titanium We
have competent program managers project and production teams with broadexperience from international developments ramp-ups and full-rate productions
KONGSBERG Aerostructures is a key supplier to several major ongoing internationalprograms such as Naval Strike Missile (NSM) Remote Weapon Station (RWS) NH-90
and F-35 We have today long-term agreements with Lockheed Martinand Northrop Grumman for the F-35 program as well as agreements with
Marvin Engineering (MEC)
KONGSBERG Aerostructures has a solid business management platform for handling largevolume programs Business results are driven through a metric and performance-based
culture with a continuous focus on risk management from start to delivered product
KONGSBERGrsquos vision is to always strive to stay in the forefront in everything we do andalways meet our customers and partners expectations and needs KONGSBERG Aerostruc-
turesrsquogoal is to deliver Affordable Products with the Right Quality at the Right Time ndash Always
OP T I MI Z I N
G
P E R F OR MA N
C E
F OR
C H A L L E
N G I N G
MI S S I ON S I N
E X T R E ME
E N V I R ON ME N T S
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983131 C O L L A B O R A T I V E 983133 WE COLLABORATE AS INDIVIDUALSAND AS AN ORGANIZATION
983131 D E T E R M I N E D 983133 WHAT WE START WE FINISHWE DO NOT GIVE IN
983131 INNOVATIVE983133 WE RELENTLESSLY PURSUEIMPROVEMENTS NEW IDEASAND NEW SOLUTIONS
983131 R E L I A B L E 983133 WE ARE RELIABLE PEOPLE WEARE RESPONSIBLE CITIZENS
KONGSBERG VALUES ARE NORMATIVE FOR HOW WE BEHAVEAND WO R K AND C HAR AC T E R I Z E S O U R C O O P E R AT I O N WI T HI NAND OUTSIDE THE KONGSBERG GROUP OUR 4 KEY VALUES ARE
KONGSBERG VALUES
Denmark Sweden
India (2)
StJohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang (China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHorten KjellerKri stiansandOsl oSandeord Sandvika StavangerStjoslashrdal SvalbardTromsoslash Trondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland (USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
KONGSBERG VISION
WORLD CLASS ndash through people technology and dedication
KONGSBERG always strives to be in the forefront and neversettle for less than world-class KONGSBERGrsquos systemsservices and products are in the international topleague ndash an achievement obtained from 200 yearsof innovation hard work and determination
KONGSBERG MISSION
Increased safety security and performance for our customers
KONGSBERG creates and delivers high technology solutionsfor people that operate under very challenging conditionson the oceans in the deep sea in defence and in spaceKONGSBERG has a mission to provide increased safetysecurity and performance for companies operatingunder such conditions
LIVING WORLD CLASS
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AREAS OF EXPERTISE
bull Pre-preg technolo gy (BMI andepoxy)
bull Composite moulding tooldesign and manufacturing (BMIsteel and Invar)
bull Design and manufacturing oftools fixtures assembly jigsbull High precision machining of
composite materialsbull Machining of
non-metallic coresbull Machining of titanium and high
alloy materialebull Surface treatment of titanium
(pre-bond etch priming)bull High speed machining
of aluminiumbull Bonded assembliesbull Integration and Assemblybull Non-Destru ctive Testing
(ultrasonic X-ray FPI)bull Manufacturing Engineeringbull Lean Six Sigma
PROGRAM REFERENCESCURRENT
bull F35 Lightning II ndash Rudders andVertical Leading Edge vari-ous Center Fuselage Parts andPylon
bull NH90 ndash Cockpit Floor
bull Naval Strike Missile (NSM) ndashAirframebull Joint Strike Missile (JSM) -
Airframebull Penguin Missile - Airframebull Remote Weapon Station (RWS)
Structural partsbull Ariane 5 ndash Booster Attachment
and Separation System
P R O G R A M R E F E R E N C E SPAST
bull Boeing 777 - FlaperonSupport Parts
bull Boeing 747 ndash Intercoastalsbull deHavilland Dash 8 - 100300 -
Tail Cones
bull Eurofighter Tyhpoon ndash InboardFlaperons amp RudderNose Landing Gear Parts
bull NH 90 ndash Main Rotor Sleevesbull Norwegian Advanced
Surface to Air Missile System(NASAMS) Launcher
bull CV90 Combat Vehicle ndashStructural parts andsub-assemblies
bull Sea Sparrow - Launcherbull Envisat ndash Platform panelsbull AeolusGOCEPlanck Galileo - Solar Array substrates
AEROSPACE amp DEFENCE983085 WORLD983085CLASS ACHIEVEMENTS
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INDUSTRY991251FIRSTCAPABILITIES983085 COMMITTED TO MAXIMIZING F98308535 PERFORMANCE
KONGSBERG provides the F-35 Lightning I Iprogram with leading technology expertiseand long-term international program experiencethrough our ski l led F-35 program - engineering-and production professionals
KONGSBERG has signed long-term contracts with the F-35Lightning II program for production of advanced compositeand metal structures as follows
JSF F98308535 RUDDER AND VERTICAL LEADING EDGE
A bonded assembly comprising machined EB welded titanium structuremulti-density core and various composite parts Delivered ready for finalassembly to Lockheed Martin Aeronautics
F98308535 CENTER FUSELAGE COMPOSITE PARTSWork Package including high tolerance composite structural panels anddoors Delivered ready for final assembly to Northrop Grumman Corporation
F98308535 AIR983085TO983085AIR PYLONSHigh speed machined aluminium structure including integration and assemblyPylons are delivered to Marvin Engineering Corporation
DETERMINEDINNOVATIVE
COLLABORATIVERELIABLE
KEY SUPPLIER ONTHE F98308535 PROGRAM
THE WORLDrsquoS ONLY5TH GENERATION
MULTIROLE STEALTHFIGHTER
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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Kongsberg Gruppen ASA ( KONGSBERG) is an internationaltechnology corporation that delivers advanced and reliablesolutions that improve safety security and performance incomplex operations and during extreme conditions
KONGSBERG is a customer focused organization with aworldwide performance culture KONGSBERG workswith demanding customers in the global defencemaritime oil and gas and aerospace industries
WORLD CLASS- through people technology and dedication
C O N T E N T SK O N G S B E R G A E R O S T R U C T U R E S
AE R O S T R U C T U R E SCenter of Excel lence - Composites and Al loys
K O NG S B E R G V AL U E S
AE R O S P AC E amp D E FE NC E
I ND U S T R Y 983085FI R S T C AP AB I L I T I E S
B R E AK T HR O U G H MI S S I L E T E C HNO L O G Y
O FFS HO R E AND S U B S E A
P RO DUCT I O N
NE W MO D E R N FAC I L I T YBui lt to support F-35 ful l - rate production
S T R AT E G I C FO C U S
E N G I N E E R I N G
E NG I NE E R I NGWorld-class expert ise
ST EP BY ST EP
C O MP O S I T E S
AD V ANC E D ME C HANI C AL MANU FAC T U R I NG
R E P AI R AND O V E R HAU L O F R O T O R C R AFTT O TAL Q UALI T Y MA N AGEMEN T
S T AT E 983085O F983085T HE 983085AR T MANU FAC T U R I NG
ME T R I C AND P E R FO R MANC E 983085B AS E D C U L T U R E
C O MP E T E NT MANAG E R S P R O G R AM983085 AND P R O D U C T I O N T E AMS
B U S I NE S S C O ND U C T
WHAT WE START WE FINISH WE DO NOT GIVE IN
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KONGSBERG creates and delivers high-technologicalsolutions to people operating under challenging conditionson the oceans in the deep sea in defence and in space KONGSBERG har facilities world-wide with over 7000employees working in more then 25 countries aroundthe world The Grouprsquos most important markets are EuropeUSA the Middle East and Asia with main focus on offshoremerchant marine and defence
KONGSBERG Defence Systems (KDS) is one of 4 strategicbusiness units in KONGSBERG KDS is Norwayrsquos leadingand major international supplier of defence and aerospacesystems and delivers products and systems for commandand control weapons guidance and sur veillance communi-cations and missiles KDS produces also advanced compositesand engineering products
KONGSBERG Aerostructures is one of six divisions underKDS with key focus on complex composites and high-alloymetal structures
KONGSBERG GROUPKONGSBERG AEROSTRUCTURES983085 CENTER OF EXCELLENCE FORCOMPOSITES AND ALLOYSA TOTAL OF 30000 SQUAREMETERS PRODUCTION AREA
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KONGSBERGAEROSTRUCTURES983085 CENTER OF EXCELLENCE 983085 COMPOSIT ES AND ALLOYS
KONGSBERG Aerostructures is a leading internationalsupplier of complex sub-assemblies to large international
manufacturers in the global aerospace and defence industryThe division also supplies the offshore and subsea market
with key structural elements and has through many yearsoffered overhaul of military rotorcraft
CO MP LEX SYSTEMS F O R EXTR EME USEKONGSBERG Aerostructures is Center of Excellence for complex composite
structures and metallic alloy assemblies and details for systems ope ratingunder extreme loads and conditions Our core capabilities ranges from
design prototyping and industrialization to large volume manufacturingfor Aerospace and other high performing markets
We offer leading manufacturing- and engineering expertise in material andprocessing technology specializing in carbon fiber composites and titanium We
have competent program managers project and production teams with broadexperience from international developments ramp-ups and full-rate productions
KONGSBERG Aerostructures is a key supplier to several major ongoing internationalprograms such as Naval Strike Missile (NSM) Remote Weapon Station (RWS) NH-90
and F-35 We have today long-term agreements with Lockheed Martinand Northrop Grumman for the F-35 program as well as agreements with
Marvin Engineering (MEC)
KONGSBERG Aerostructures has a solid business management platform for handling largevolume programs Business results are driven through a metric and performance-based
culture with a continuous focus on risk management from start to delivered product
KONGSBERGrsquos vision is to always strive to stay in the forefront in everything we do andalways meet our customers and partners expectations and needs KONGSBERG Aerostruc-
turesrsquogoal is to deliver Affordable Products with the Right Quality at the Right Time ndash Always
OP T I MI Z I N
G
P E R F OR MA N
C E
F OR
C H A L L E
N G I N G
MI S S I ON S I N
E X T R E ME
E N V I R ON ME N T S
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983131 C O L L A B O R A T I V E 983133 WE COLLABORATE AS INDIVIDUALSAND AS AN ORGANIZATION
983131 D E T E R M I N E D 983133 WHAT WE START WE FINISHWE DO NOT GIVE IN
983131 INNOVATIVE983133 WE RELENTLESSLY PURSUEIMPROVEMENTS NEW IDEASAND NEW SOLUTIONS
983131 R E L I A B L E 983133 WE ARE RELIABLE PEOPLE WEARE RESPONSIBLE CITIZENS
KONGSBERG VALUES ARE NORMATIVE FOR HOW WE BEHAVEAND WO R K AND C HAR AC T E R I Z E S O U R C O O P E R AT I O N WI T HI NAND OUTSIDE THE KONGSBERG GROUP OUR 4 KEY VALUES ARE
KONGSBERG VALUES
Denmark Sweden
India (2)
StJohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang (China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHorten KjellerKri stiansandOsl oSandeord Sandvika StavangerStjoslashrdal SvalbardTromsoslash Trondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland (USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
KONGSBERG VISION
WORLD CLASS ndash through people technology and dedication
KONGSBERG always strives to be in the forefront and neversettle for less than world-class KONGSBERGrsquos systemsservices and products are in the international topleague ndash an achievement obtained from 200 yearsof innovation hard work and determination
KONGSBERG MISSION
Increased safety security and performance for our customers
KONGSBERG creates and delivers high technology solutionsfor people that operate under very challenging conditionson the oceans in the deep sea in defence and in spaceKONGSBERG has a mission to provide increased safetysecurity and performance for companies operatingunder such conditions
LIVING WORLD CLASS
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AREAS OF EXPERTISE
bull Pre-preg technolo gy (BMI andepoxy)
bull Composite moulding tooldesign and manufacturing (BMIsteel and Invar)
bull Design and manufacturing oftools fixtures assembly jigsbull High precision machining of
composite materialsbull Machining of
non-metallic coresbull Machining of titanium and high
alloy materialebull Surface treatment of titanium
(pre-bond etch priming)bull High speed machining
of aluminiumbull Bonded assembliesbull Integration and Assemblybull Non-Destru ctive Testing
(ultrasonic X-ray FPI)bull Manufacturing Engineeringbull Lean Six Sigma
PROGRAM REFERENCESCURRENT
bull F35 Lightning II ndash Rudders andVertical Leading Edge vari-ous Center Fuselage Parts andPylon
bull NH90 ndash Cockpit Floor
bull Naval Strike Missile (NSM) ndashAirframebull Joint Strike Missile (JSM) -
Airframebull Penguin Missile - Airframebull Remote Weapon Station (RWS)
Structural partsbull Ariane 5 ndash Booster Attachment
and Separation System
P R O G R A M R E F E R E N C E SPAST
bull Boeing 777 - FlaperonSupport Parts
bull Boeing 747 ndash Intercoastalsbull deHavilland Dash 8 - 100300 -
Tail Cones
bull Eurofighter Tyhpoon ndash InboardFlaperons amp RudderNose Landing Gear Parts
bull NH 90 ndash Main Rotor Sleevesbull Norwegian Advanced
Surface to Air Missile System(NASAMS) Launcher
bull CV90 Combat Vehicle ndashStructural parts andsub-assemblies
bull Sea Sparrow - Launcherbull Envisat ndash Platform panelsbull AeolusGOCEPlanck Galileo - Solar Array substrates
AEROSPACE amp DEFENCE983085 WORLD983085CLASS ACHIEVEMENTS
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INDUSTRY991251FIRSTCAPABILITIES983085 COMMITTED TO MAXIMIZING F98308535 PERFORMANCE
KONGSBERG provides the F-35 Lightning I Iprogram with leading technology expertiseand long-term international program experiencethrough our ski l led F-35 program - engineering-and production professionals
KONGSBERG has signed long-term contracts with the F-35Lightning II program for production of advanced compositeand metal structures as follows
JSF F98308535 RUDDER AND VERTICAL LEADING EDGE
A bonded assembly comprising machined EB welded titanium structuremulti-density core and various composite parts Delivered ready for finalassembly to Lockheed Martin Aeronautics
F98308535 CENTER FUSELAGE COMPOSITE PARTSWork Package including high tolerance composite structural panels anddoors Delivered ready for final assembly to Northrop Grumman Corporation
F98308535 AIR983085TO983085AIR PYLONSHigh speed machined aluminium structure including integration and assemblyPylons are delivered to Marvin Engineering Corporation
DETERMINEDINNOVATIVE
COLLABORATIVERELIABLE
KEY SUPPLIER ONTHE F98308535 PROGRAM
THE WORLDrsquoS ONLY5TH GENERATION
MULTIROLE STEALTHFIGHTER
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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KONGSBERG creates and delivers high-technologicalsolutions to people operating under challenging conditionson the oceans in the deep sea in defence and in space KONGSBERG har facilities world-wide with over 7000employees working in more then 25 countries aroundthe world The Grouprsquos most important markets are EuropeUSA the Middle East and Asia with main focus on offshoremerchant marine and defence
KONGSBERG Defence Systems (KDS) is one of 4 strategicbusiness units in KONGSBERG KDS is Norwayrsquos leadingand major international supplier of defence and aerospacesystems and delivers products and systems for commandand control weapons guidance and sur veillance communi-cations and missiles KDS produces also advanced compositesand engineering products
KONGSBERG Aerostructures is one of six divisions underKDS with key focus on complex composites and high-alloymetal structures
KONGSBERG GROUPKONGSBERG AEROSTRUCTURES983085 CENTER OF EXCELLENCE FORCOMPOSITES AND ALLOYSA TOTAL OF 30000 SQUAREMETERS PRODUCTION AREA
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KONGSBERGAEROSTRUCTURES983085 CENTER OF EXCELLENCE 983085 COMPOSIT ES AND ALLOYS
KONGSBERG Aerostructures is a leading internationalsupplier of complex sub-assemblies to large international
manufacturers in the global aerospace and defence industryThe division also supplies the offshore and subsea market
with key structural elements and has through many yearsoffered overhaul of military rotorcraft
CO MP LEX SYSTEMS F O R EXTR EME USEKONGSBERG Aerostructures is Center of Excellence for complex composite
structures and metallic alloy assemblies and details for systems ope ratingunder extreme loads and conditions Our core capabilities ranges from
design prototyping and industrialization to large volume manufacturingfor Aerospace and other high performing markets
We offer leading manufacturing- and engineering expertise in material andprocessing technology specializing in carbon fiber composites and titanium We
have competent program managers project and production teams with broadexperience from international developments ramp-ups and full-rate productions
KONGSBERG Aerostructures is a key supplier to several major ongoing internationalprograms such as Naval Strike Missile (NSM) Remote Weapon Station (RWS) NH-90
and F-35 We have today long-term agreements with Lockheed Martinand Northrop Grumman for the F-35 program as well as agreements with
Marvin Engineering (MEC)
KONGSBERG Aerostructures has a solid business management platform for handling largevolume programs Business results are driven through a metric and performance-based
culture with a continuous focus on risk management from start to delivered product
KONGSBERGrsquos vision is to always strive to stay in the forefront in everything we do andalways meet our customers and partners expectations and needs KONGSBERG Aerostruc-
turesrsquogoal is to deliver Affordable Products with the Right Quality at the Right Time ndash Always
OP T I MI Z I N
G
P E R F OR MA N
C E
F OR
C H A L L E
N G I N G
MI S S I ON S I N
E X T R E ME
E N V I R ON ME N T S
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983131 C O L L A B O R A T I V E 983133 WE COLLABORATE AS INDIVIDUALSAND AS AN ORGANIZATION
983131 D E T E R M I N E D 983133 WHAT WE START WE FINISHWE DO NOT GIVE IN
983131 INNOVATIVE983133 WE RELENTLESSLY PURSUEIMPROVEMENTS NEW IDEASAND NEW SOLUTIONS
983131 R E L I A B L E 983133 WE ARE RELIABLE PEOPLE WEARE RESPONSIBLE CITIZENS
KONGSBERG VALUES ARE NORMATIVE FOR HOW WE BEHAVEAND WO R K AND C HAR AC T E R I Z E S O U R C O O P E R AT I O N WI T HI NAND OUTSIDE THE KONGSBERG GROUP OUR 4 KEY VALUES ARE
KONGSBERG VALUES
Denmark Sweden
India (2)
StJohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang (China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHorten KjellerKri stiansandOsl oSandeord Sandvika StavangerStjoslashrdal SvalbardTromsoslash Trondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland (USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
KONGSBERG VISION
WORLD CLASS ndash through people technology and dedication
KONGSBERG always strives to be in the forefront and neversettle for less than world-class KONGSBERGrsquos systemsservices and products are in the international topleague ndash an achievement obtained from 200 yearsof innovation hard work and determination
KONGSBERG MISSION
Increased safety security and performance for our customers
KONGSBERG creates and delivers high technology solutionsfor people that operate under very challenging conditionson the oceans in the deep sea in defence and in spaceKONGSBERG has a mission to provide increased safetysecurity and performance for companies operatingunder such conditions
LIVING WORLD CLASS
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AREAS OF EXPERTISE
bull Pre-preg technolo gy (BMI andepoxy)
bull Composite moulding tooldesign and manufacturing (BMIsteel and Invar)
bull Design and manufacturing oftools fixtures assembly jigsbull High precision machining of
composite materialsbull Machining of
non-metallic coresbull Machining of titanium and high
alloy materialebull Surface treatment of titanium
(pre-bond etch priming)bull High speed machining
of aluminiumbull Bonded assembliesbull Integration and Assemblybull Non-Destru ctive Testing
(ultrasonic X-ray FPI)bull Manufacturing Engineeringbull Lean Six Sigma
PROGRAM REFERENCESCURRENT
bull F35 Lightning II ndash Rudders andVertical Leading Edge vari-ous Center Fuselage Parts andPylon
bull NH90 ndash Cockpit Floor
bull Naval Strike Missile (NSM) ndashAirframebull Joint Strike Missile (JSM) -
Airframebull Penguin Missile - Airframebull Remote Weapon Station (RWS)
Structural partsbull Ariane 5 ndash Booster Attachment
and Separation System
P R O G R A M R E F E R E N C E SPAST
bull Boeing 777 - FlaperonSupport Parts
bull Boeing 747 ndash Intercoastalsbull deHavilland Dash 8 - 100300 -
Tail Cones
bull Eurofighter Tyhpoon ndash InboardFlaperons amp RudderNose Landing Gear Parts
bull NH 90 ndash Main Rotor Sleevesbull Norwegian Advanced
Surface to Air Missile System(NASAMS) Launcher
bull CV90 Combat Vehicle ndashStructural parts andsub-assemblies
bull Sea Sparrow - Launcherbull Envisat ndash Platform panelsbull AeolusGOCEPlanck Galileo - Solar Array substrates
AEROSPACE amp DEFENCE983085 WORLD983085CLASS ACHIEVEMENTS
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INDUSTRY991251FIRSTCAPABILITIES983085 COMMITTED TO MAXIMIZING F98308535 PERFORMANCE
KONGSBERG provides the F-35 Lightning I Iprogram with leading technology expertiseand long-term international program experiencethrough our ski l led F-35 program - engineering-and production professionals
KONGSBERG has signed long-term contracts with the F-35Lightning II program for production of advanced compositeand metal structures as follows
JSF F98308535 RUDDER AND VERTICAL LEADING EDGE
A bonded assembly comprising machined EB welded titanium structuremulti-density core and various composite parts Delivered ready for finalassembly to Lockheed Martin Aeronautics
F98308535 CENTER FUSELAGE COMPOSITE PARTSWork Package including high tolerance composite structural panels anddoors Delivered ready for final assembly to Northrop Grumman Corporation
F98308535 AIR983085TO983085AIR PYLONSHigh speed machined aluminium structure including integration and assemblyPylons are delivered to Marvin Engineering Corporation
DETERMINEDINNOVATIVE
COLLABORATIVERELIABLE
KEY SUPPLIER ONTHE F98308535 PROGRAM
THE WORLDrsquoS ONLY5TH GENERATION
MULTIROLE STEALTHFIGHTER
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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KONGSBERGAEROSTRUCTURES983085 CENTER OF EXCELLENCE 983085 COMPOSIT ES AND ALLOYS
KONGSBERG Aerostructures is a leading internationalsupplier of complex sub-assemblies to large international
manufacturers in the global aerospace and defence industryThe division also supplies the offshore and subsea market
with key structural elements and has through many yearsoffered overhaul of military rotorcraft
CO MP LEX SYSTEMS F O R EXTR EME USEKONGSBERG Aerostructures is Center of Excellence for complex composite
structures and metallic alloy assemblies and details for systems ope ratingunder extreme loads and conditions Our core capabilities ranges from
design prototyping and industrialization to large volume manufacturingfor Aerospace and other high performing markets
We offer leading manufacturing- and engineering expertise in material andprocessing technology specializing in carbon fiber composites and titanium We
have competent program managers project and production teams with broadexperience from international developments ramp-ups and full-rate productions
KONGSBERG Aerostructures is a key supplier to several major ongoing internationalprograms such as Naval Strike Missile (NSM) Remote Weapon Station (RWS) NH-90
and F-35 We have today long-term agreements with Lockheed Martinand Northrop Grumman for the F-35 program as well as agreements with
Marvin Engineering (MEC)
KONGSBERG Aerostructures has a solid business management platform for handling largevolume programs Business results are driven through a metric and performance-based
culture with a continuous focus on risk management from start to delivered product
KONGSBERGrsquos vision is to always strive to stay in the forefront in everything we do andalways meet our customers and partners expectations and needs KONGSBERG Aerostruc-
turesrsquogoal is to deliver Affordable Products with the Right Quality at the Right Time ndash Always
OP T I MI Z I N
G
P E R F OR MA N
C E
F OR
C H A L L E
N G I N G
MI S S I ON S I N
E X T R E ME
E N V I R ON ME N T S
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983131 C O L L A B O R A T I V E 983133 WE COLLABORATE AS INDIVIDUALSAND AS AN ORGANIZATION
983131 D E T E R M I N E D 983133 WHAT WE START WE FINISHWE DO NOT GIVE IN
983131 INNOVATIVE983133 WE RELENTLESSLY PURSUEIMPROVEMENTS NEW IDEASAND NEW SOLUTIONS
983131 R E L I A B L E 983133 WE ARE RELIABLE PEOPLE WEARE RESPONSIBLE CITIZENS
KONGSBERG VALUES ARE NORMATIVE FOR HOW WE BEHAVEAND WO R K AND C HAR AC T E R I Z E S O U R C O O P E R AT I O N WI T HI NAND OUTSIDE THE KONGSBERG GROUP OUR 4 KEY VALUES ARE
KONGSBERG VALUES
Denmark Sweden
India (2)
StJohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang (China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHorten KjellerKri stiansandOsl oSandeord Sandvika StavangerStjoslashrdal SvalbardTromsoslash Trondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland (USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
KONGSBERG VISION
WORLD CLASS ndash through people technology and dedication
KONGSBERG always strives to be in the forefront and neversettle for less than world-class KONGSBERGrsquos systemsservices and products are in the international topleague ndash an achievement obtained from 200 yearsof innovation hard work and determination
KONGSBERG MISSION
Increased safety security and performance for our customers
KONGSBERG creates and delivers high technology solutionsfor people that operate under very challenging conditionson the oceans in the deep sea in defence and in spaceKONGSBERG has a mission to provide increased safetysecurity and performance for companies operatingunder such conditions
LIVING WORLD CLASS
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AREAS OF EXPERTISE
bull Pre-preg technolo gy (BMI andepoxy)
bull Composite moulding tooldesign and manufacturing (BMIsteel and Invar)
bull Design and manufacturing oftools fixtures assembly jigsbull High precision machining of
composite materialsbull Machining of
non-metallic coresbull Machining of titanium and high
alloy materialebull Surface treatment of titanium
(pre-bond etch priming)bull High speed machining
of aluminiumbull Bonded assembliesbull Integration and Assemblybull Non-Destru ctive Testing
(ultrasonic X-ray FPI)bull Manufacturing Engineeringbull Lean Six Sigma
PROGRAM REFERENCESCURRENT
bull F35 Lightning II ndash Rudders andVertical Leading Edge vari-ous Center Fuselage Parts andPylon
bull NH90 ndash Cockpit Floor
bull Naval Strike Missile (NSM) ndashAirframebull Joint Strike Missile (JSM) -
Airframebull Penguin Missile - Airframebull Remote Weapon Station (RWS)
Structural partsbull Ariane 5 ndash Booster Attachment
and Separation System
P R O G R A M R E F E R E N C E SPAST
bull Boeing 777 - FlaperonSupport Parts
bull Boeing 747 ndash Intercoastalsbull deHavilland Dash 8 - 100300 -
Tail Cones
bull Eurofighter Tyhpoon ndash InboardFlaperons amp RudderNose Landing Gear Parts
bull NH 90 ndash Main Rotor Sleevesbull Norwegian Advanced
Surface to Air Missile System(NASAMS) Launcher
bull CV90 Combat Vehicle ndashStructural parts andsub-assemblies
bull Sea Sparrow - Launcherbull Envisat ndash Platform panelsbull AeolusGOCEPlanck Galileo - Solar Array substrates
AEROSPACE amp DEFENCE983085 WORLD983085CLASS ACHIEVEMENTS
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INDUSTRY991251FIRSTCAPABILITIES983085 COMMITTED TO MAXIMIZING F98308535 PERFORMANCE
KONGSBERG provides the F-35 Lightning I Iprogram with leading technology expertiseand long-term international program experiencethrough our ski l led F-35 program - engineering-and production professionals
KONGSBERG has signed long-term contracts with the F-35Lightning II program for production of advanced compositeand metal structures as follows
JSF F98308535 RUDDER AND VERTICAL LEADING EDGE
A bonded assembly comprising machined EB welded titanium structuremulti-density core and various composite parts Delivered ready for finalassembly to Lockheed Martin Aeronautics
F98308535 CENTER FUSELAGE COMPOSITE PARTSWork Package including high tolerance composite structural panels anddoors Delivered ready for final assembly to Northrop Grumman Corporation
F98308535 AIR983085TO983085AIR PYLONSHigh speed machined aluminium structure including integration and assemblyPylons are delivered to Marvin Engineering Corporation
DETERMINEDINNOVATIVE
COLLABORATIVERELIABLE
KEY SUPPLIER ONTHE F98308535 PROGRAM
THE WORLDrsquoS ONLY5TH GENERATION
MULTIROLE STEALTHFIGHTER
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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983131 C O L L A B O R A T I V E 983133 WE COLLABORATE AS INDIVIDUALSAND AS AN ORGANIZATION
983131 D E T E R M I N E D 983133 WHAT WE START WE FINISHWE DO NOT GIVE IN
983131 INNOVATIVE983133 WE RELENTLESSLY PURSUEIMPROVEMENTS NEW IDEASAND NEW SOLUTIONS
983131 R E L I A B L E 983133 WE ARE RELIABLE PEOPLE WEARE RESPONSIBLE CITIZENS
KONGSBERG VALUES ARE NORMATIVE FOR HOW WE BEHAVEAND WO R K AND C HAR AC T E R I Z E S O U R C O O P E R AT I O N WI T HI NAND OUTSIDE THE KONGSBERG GROUP OUR 4 KEY VALUES ARE
KONGSBERG VALUES
Denmark Sweden
India (2)
StJohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang (China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHorten KjellerKri stiansandOsl oSandeord Sandvika StavangerStjoslashrdal SvalbardTromsoslash Trondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland (USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
KONGSBERG VISION
WORLD CLASS ndash through people technology and dedication
KONGSBERG always strives to be in the forefront and neversettle for less than world-class KONGSBERGrsquos systemsservices and products are in the international topleague ndash an achievement obtained from 200 yearsof innovation hard work and determination
KONGSBERG MISSION
Increased safety security and performance for our customers
KONGSBERG creates and delivers high technology solutionsfor people that operate under very challenging conditionson the oceans in the deep sea in defence and in spaceKONGSBERG has a mission to provide increased safetysecurity and performance for companies operatingunder such conditions
LIVING WORLD CLASS
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AREAS OF EXPERTISE
bull Pre-preg technolo gy (BMI andepoxy)
bull Composite moulding tooldesign and manufacturing (BMIsteel and Invar)
bull Design and manufacturing oftools fixtures assembly jigsbull High precision machining of
composite materialsbull Machining of
non-metallic coresbull Machining of titanium and high
alloy materialebull Surface treatment of titanium
(pre-bond etch priming)bull High speed machining
of aluminiumbull Bonded assembliesbull Integration and Assemblybull Non-Destru ctive Testing
(ultrasonic X-ray FPI)bull Manufacturing Engineeringbull Lean Six Sigma
PROGRAM REFERENCESCURRENT
bull F35 Lightning II ndash Rudders andVertical Leading Edge vari-ous Center Fuselage Parts andPylon
bull NH90 ndash Cockpit Floor
bull Naval Strike Missile (NSM) ndashAirframebull Joint Strike Missile (JSM) -
Airframebull Penguin Missile - Airframebull Remote Weapon Station (RWS)
Structural partsbull Ariane 5 ndash Booster Attachment
and Separation System
P R O G R A M R E F E R E N C E SPAST
bull Boeing 777 - FlaperonSupport Parts
bull Boeing 747 ndash Intercoastalsbull deHavilland Dash 8 - 100300 -
Tail Cones
bull Eurofighter Tyhpoon ndash InboardFlaperons amp RudderNose Landing Gear Parts
bull NH 90 ndash Main Rotor Sleevesbull Norwegian Advanced
Surface to Air Missile System(NASAMS) Launcher
bull CV90 Combat Vehicle ndashStructural parts andsub-assemblies
bull Sea Sparrow - Launcherbull Envisat ndash Platform panelsbull AeolusGOCEPlanck Galileo - Solar Array substrates
AEROSPACE amp DEFENCE983085 WORLD983085CLASS ACHIEVEMENTS
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INDUSTRY991251FIRSTCAPABILITIES983085 COMMITTED TO MAXIMIZING F98308535 PERFORMANCE
KONGSBERG provides the F-35 Lightning I Iprogram with leading technology expertiseand long-term international program experiencethrough our ski l led F-35 program - engineering-and production professionals
KONGSBERG has signed long-term contracts with the F-35Lightning II program for production of advanced compositeand metal structures as follows
JSF F98308535 RUDDER AND VERTICAL LEADING EDGE
A bonded assembly comprising machined EB welded titanium structuremulti-density core and various composite parts Delivered ready for finalassembly to Lockheed Martin Aeronautics
F98308535 CENTER FUSELAGE COMPOSITE PARTSWork Package including high tolerance composite structural panels anddoors Delivered ready for final assembly to Northrop Grumman Corporation
F98308535 AIR983085TO983085AIR PYLONSHigh speed machined aluminium structure including integration and assemblyPylons are delivered to Marvin Engineering Corporation
DETERMINEDINNOVATIVE
COLLABORATIVERELIABLE
KEY SUPPLIER ONTHE F98308535 PROGRAM
THE WORLDrsquoS ONLY5TH GENERATION
MULTIROLE STEALTHFIGHTER
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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AREAS OF EXPERTISE
bull Pre-preg technolo gy (BMI andepoxy)
bull Composite moulding tooldesign and manufacturing (BMIsteel and Invar)
bull Design and manufacturing oftools fixtures assembly jigsbull High precision machining of
composite materialsbull Machining of
non-metallic coresbull Machining of titanium and high
alloy materialebull Surface treatment of titanium
(pre-bond etch priming)bull High speed machining
of aluminiumbull Bonded assembliesbull Integration and Assemblybull Non-Destru ctive Testing
(ultrasonic X-ray FPI)bull Manufacturing Engineeringbull Lean Six Sigma
PROGRAM REFERENCESCURRENT
bull F35 Lightning II ndash Rudders andVertical Leading Edge vari-ous Center Fuselage Parts andPylon
bull NH90 ndash Cockpit Floor
bull Naval Strike Missile (NSM) ndashAirframebull Joint Strike Missile (JSM) -
Airframebull Penguin Missile - Airframebull Remote Weapon Station (RWS)
Structural partsbull Ariane 5 ndash Booster Attachment
and Separation System
P R O G R A M R E F E R E N C E SPAST
bull Boeing 777 - FlaperonSupport Parts
bull Boeing 747 ndash Intercoastalsbull deHavilland Dash 8 - 100300 -
Tail Cones
bull Eurofighter Tyhpoon ndash InboardFlaperons amp RudderNose Landing Gear Parts
bull NH 90 ndash Main Rotor Sleevesbull Norwegian Advanced
Surface to Air Missile System(NASAMS) Launcher
bull CV90 Combat Vehicle ndashStructural parts andsub-assemblies
bull Sea Sparrow - Launcherbull Envisat ndash Platform panelsbull AeolusGOCEPlanck Galileo - Solar Array substrates
AEROSPACE amp DEFENCE983085 WORLD983085CLASS ACHIEVEMENTS
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INDUSTRY991251FIRSTCAPABILITIES983085 COMMITTED TO MAXIMIZING F98308535 PERFORMANCE
KONGSBERG provides the F-35 Lightning I Iprogram with leading technology expertiseand long-term international program experiencethrough our ski l led F-35 program - engineering-and production professionals
KONGSBERG has signed long-term contracts with the F-35Lightning II program for production of advanced compositeand metal structures as follows
JSF F98308535 RUDDER AND VERTICAL LEADING EDGE
A bonded assembly comprising machined EB welded titanium structuremulti-density core and various composite parts Delivered ready for finalassembly to Lockheed Martin Aeronautics
F98308535 CENTER FUSELAGE COMPOSITE PARTSWork Package including high tolerance composite structural panels anddoors Delivered ready for final assembly to Northrop Grumman Corporation
F98308535 AIR983085TO983085AIR PYLONSHigh speed machined aluminium structure including integration and assemblyPylons are delivered to Marvin Engineering Corporation
DETERMINEDINNOVATIVE
COLLABORATIVERELIABLE
KEY SUPPLIER ONTHE F98308535 PROGRAM
THE WORLDrsquoS ONLY5TH GENERATION
MULTIROLE STEALTHFIGHTER
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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INDUSTRY991251FIRSTCAPABILITIES983085 COMMITTED TO MAXIMIZING F98308535 PERFORMANCE
KONGSBERG provides the F-35 Lightning I Iprogram with leading technology expertiseand long-term international program experiencethrough our ski l led F-35 program - engineering-and production professionals
KONGSBERG has signed long-term contracts with the F-35Lightning II program for production of advanced compositeand metal structures as follows
JSF F98308535 RUDDER AND VERTICAL LEADING EDGE
A bonded assembly comprising machined EB welded titanium structuremulti-density core and various composite parts Delivered ready for finalassembly to Lockheed Martin Aeronautics
F98308535 CENTER FUSELAGE COMPOSITE PARTSWork Package including high tolerance composite structural panels anddoors Delivered ready for final assembly to Northrop Grumman Corporation
F98308535 AIR983085TO983085AIR PYLONSHigh speed machined aluminium structure including integration and assemblyPylons are delivered to Marvin Engineering Corporation
DETERMINEDINNOVATIVE
COLLABORATIVERELIABLE
KEY SUPPLIER ONTHE F98308535 PROGRAM
THE WORLDrsquoS ONLY5TH GENERATION
MULTIROLE STEALTHFIGHTER
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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KONGSBERGRELENTLESSLY PURSUES
IMPROVEMENTSNEW IDEAS AND NEW
SOLUTIONS
BREAKTHROUGHMISSILE TECHNOLOGY983085 OFFERING A KONGSBERG FAMILY OF HIGH983085PRECISION STRIKE MISSILES
KONGSBERG has been prime contractor in cruise missile design development andmanufacturing for over 40 years The Penguin Anti-Ship Missile developed in thesixties is still one of the preferred anti-ship weapons carried by helicopters
The Naval Strike Missile (NSM) and the Joint Strike Missile (JSM) represent thelatest generation of Precision Strike Missiles from KONGSBERG the JSM is stillunder development
The NSM is today marketed for naval ships and coast defence systems on thelatter the missile is launched from trucks The JSM is designed to be carriedboth externally and internally in the weapons bay of the F-35 Lightning II
Both missiles have a passive imaging IR seeker and combined with high maneuver-ability and low signature they are able to penetrate highly defended targets bothat land and sea High maneuverability is achieved by high aerodynamic efficiencyand an all composite airframe
KONGSBERG as prime contractor is involved from Conops (Concept of Operation)developed together with our customer through to design and development of themissile A number of the sub-systems in the missile is designed and developedby KONGSBERG hence this gives KONGSBERG a good understanding of trade-offsrequired in aerospace design and development work
PROTOTYPING AND PRODUCTIONOF AIRFRAMES AND CONTROL
SURFACES FOR THE JOINTSTRIKE MISSILE 983080JSM983081 PROGRAM
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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KONGSBERG operates within a multitude of areas in the oil andgas industry including KONGSBERG Aerostructures supplyingkey structural elements to the subsea market Current productgroups are tie-in and manifold systems were our keydeliverables are
bull Umbilicals and Jumper Spoolsbull Connectorsbull Hubsbull Termination Headsbull Clampsbull Manifold Blocks
We have a clear ambition to deliver products and services
higher in the value chain that includes design and systemdeliveries Core competence covers
bull Complex machiningbull Cladding (In-lay welding)bull Electron Beam Weldingbull Welding robotics for large volumesbull NDT ndash Ultrasound and x-raybull Assemblybull Testingbull Program and project managementbull Engineering supportbull Strong supplier network
Pictures from our production of products
OFFSHOREAND SUBSEA983085 E XP E R I E NC E D K NO WL E D G AB L E AND C O MMI T T E D
OFFERING BROADENGINEERING EXPERTISE
MODERN PRODUCTIONEQUIPMENT AND A STRONG
QUALITY MANAGEMENTCULTURE DATING BACK TO 1814
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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NEWMODERN FACILITY983085 B U I L T T O S U P P O R T F9830853 5 FU L L 983085R AT E P R O D U C T I O N
KONGSBERGS new modern facility ARSENALET opened in2008 and provides a total of 30000 square meters produc-tion area Composite activities are operating two-thirds of thetotal area and mechanical operations one-third 4500 squaremeters is allocated to an administrative building
ARSENALET is constructed to support a high production rateFacility design and shop floor lay-up can easily be expandedwith little interruption to ongoing production The facilityand equipment are in excellent condition due to low ageand an optimal maintenance program
Maintenance is fully outsourced to Kongsberg Terotech ASwhich is a 5050 joint ownership between KongsbergDefence and Aerospace (KDA) and Volvo Aero Norge ASA frame agreement with Kongsberg Terotech AS ensuresdedicated and efficient maintenance and repair servicesof AEROSTRUCTURES total equipment park
bull F LEXIBLE SHO P F LO O R LA YO UTbull LO W A GE EQ UIP MENTbull O P TIMA L MA INTENA NCE
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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AUTOMATION AND STANDARDIZATION
KONGSBERGS efficiency goal is a 247 utilization of productionequipment Available are flexible manufacturing systems withhighly automated 4-5 axis machining centers constituting amanufacturing facility built for high volumes of complexparts The functionality of these machines enables us torun our production efficiently with low manning
Q U A L I T Y A N D O N 983085 T I M E D E L I V E R Y
KONGSBERG has long-term experience in manufacturinghigh-quality products with strict requirements and tighttolerances destined for operating under extreme conditions
Safety Quality and Performance is important to our customer and is akey focus through KONGSBERGS total value chain from supply chainthrough manufacturing and to delivered end-product
RISK MANAGEMENT AND MITIGATION
KONGSBERG has rigorous processes for risk management andmitigation Risk management is a key focus with KONGSBERGSprogram managers from design and development stage todelivery of final product to our customers
STRATEGIC FOCUS EFFICIENTPRODUCTION THROUGHSTANDARDIZATIONAUTOMATION ANDUNMANNED MACHINING
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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IN983085HOUSE SPECIALPROCESSES OFFERSFULL CONTROLOF PERFORMANCE
L I S T O F C US T O MER APPR O VED PR O C ES S ES
NAS 410 Certification amp Qualification of Nondestructive Test PersonnelMIL-DTL-5002 Degreasing of aluminiumLMA-PG001 Pre-Penetrant Etch TitaniumMIL-F-18264 PrimepaintAMS 2801AMS 2750 Heat Treatment of Titanium Alloy PartsLMA-PE007 Electron Beam WeldingLMA-PC001 Ultrasonic InspectionASTM E1742 Radiographic ExaminationLMA-PC201 Fluorescent Penetrant InspectionLMA-PC301 Radiographic InspectionNS-EN 3834ASME IXNACE- NR175NORSOK standards Welding standards
ENGINEERING983085 W O R L D 983085 C L A S S E X P E R T I S E
KONGSBERG is the premier aerospace engineering environ-ment in Norway KONGSBERG is a prime contractor in cruisemissile development and manufacturer of aerostructuresAdditionally KONGSBERG design develop and qualifycomplex space subsystem for launchers and satellites
MECHA NICA L D ESIGN amp D EV ELO P MENTbull Computer Aided Design ndash
Catia V5 FiberSimtrade SolidWorksbull Finite Element Analysis ndash MSCSoftware
tooling suite CATIA V5bull Computational Fluid Dynamics ndash Cobaltbull Thermodynamics ndash MSCSoftware CF Design
MA NUF A CTUR ING ENGINEER ING
bull Computer Aided Manufacturing ndashMasterCam CATIA and VeriCut
bull Manufacturing Execution System ndash SAP-MEbull Design and manufacturing of tools fixtures
assembly jigsbull Lean and Six Sigma implementation
TESTINGbull Material testing including establishing
design allowablesbull Static and dynamics structural testingbull Flight Testingbull Environmental testing
bull EMC testing
IN983085 HO USE SP ECIA L P R O CESSCA P A BILITY A ND CER TIF ICA TIO N
bull Composite (Epoxy BMI monolithic sandwichbonding potting riveting ClickBond)
bull Chemical Etchingbull Heat Treatmentbull Electron Beam Weldingbull Hard Surface Weldingbull Prime and Paintbull Grit Blastingbull NDT (X-ray Ultrasoni c and FPI)
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1925
COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
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7242019 Aero Structure
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
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WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
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N O TE SN OT E S
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NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
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ADVANCED MECHANICALMANUFACTURING983085FOR LARGE VOLUMES OF COMPLEX ALLOYS
MA CHINING W O R KSHO P
bull 11 machining centersbull 2 x 4-axis machining centersbull 3 x millturn with 1 x 9-axis with
geantry and pallettsbull 1 x FMS workshop with 2 x 4-axis
and 2 x 5-axis machining centersintegrated together with a washing machine
W ELD ING W O R KSHO P
Offering effective serial production of high volume productsbull 9 manual welding pointsbull Welding robotbull Hot wire tig for in-lay welding of Inconellbull Necessary equipment to buckle and
cut sheet metal
TO O LS A ND P R O TO TYP E W O R KSHO P
Offering a varied selection of equipment to design andmanufacture production equipment (jigs and specialmeasuring instruments) and prototypesbull CNC machines (turn and mill)bull Grinding machines (round plane and
coordinate jig grinding machine)bull Honing equipmentbull Coordinate jig boring machinesbull A varied selection of manual machinesbull Coordinate jig bores and jig grinding
machines are located in a separatetemperature controlled room
KO NGSBER G A ER O STR UCTUR ES
Manufacturing Capabilities andCapacities are found in detail in our separateManufacturing Capabilities List
KONGSBERGS mechanical expertise comprises three central areas machiningwelding and sheet metal production and development of tools and prototypesAll areas of the department have production equipment with a low average ageand run by skilled trained operators Focus is on automation
HIGHLY AUTOMATED 49830855983085AXISMACHINING CENTERS RUN BY
SKILLED MANUFACTURINGPROFESSIONALS
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Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
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REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
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bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
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TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
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httpslidepdfcomreaderfullaero-structure 1925
COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
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httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
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httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1525
Fully integrated FMS system including 4 machines and awashing machine enables us to manufacture a wide rangeof products All from high alloy to high speed aluminummachining (33000rpm)
In order to environmentally seal the composite partassembly various types of paints are sprayed onto the partThis can be done manually or using a robotKONGSBERG uses a CNC Robot ABB with a painting area of2100 x 4400 mm To enhance bonding properties primersare also sprayed onto the details
Fully automated and NC-controlled EB-welding machineare used for products with high degree of accuracy andcomplex structures We are also certified to do EB-weldingrepair in controlled environment
AUTO MATED MACHINING4EB983085WELD ING3
PRIME AND PAINT
7 8CMM amp MANUAL INSPECTIO N
4 to 9-axis machines manufacture advanced productsfrom aluminum to high alloy Semi-automation andpallets enable us to minimize changeover time
Our Makino machine center includes 3 A8192 and 3 MCD2530 with both 4 and 5-axis capabilities manufacturingcomplex titanium high-alloy and aluminum productsThe machine pallet-system ensures a high degree ofautomation and unmanned production
Rapid prototyping and small size serial prodution isperformed in 3-axis machines by highly skilled operatorsOur NC-controlled jig bore machine manufacture advancedfixtures and tailored measuring equipment Various grindingmachines ensures our capability to manufacture productswith high degree of surface finish and accuracy
Hotwire tig overlay of Inconel for advanced products is ourspecialty for some of our customers Together withrobotized welding machine for advanced sheet metaltubes and bend welding in super duplex and a line of manual welding stations our capability has a wide range tooffer Our welders also support tooling in rapid prototyping
TO O LING1 WELD ING2
AD VANCED MACHINING
5MAKINO MACHINE CENTER
6
3 CMM machines and several certified inspectors ensurethat our products are delivered to customer specifications
ONE OF EUROPErsquoS MOSTADVANCED MANUFACTURERS
OF COMPLEX STRUCTURESIN HIGH983085ALLOY METALS
SPECIALIZING IN TITANIUM
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1625
REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1725
bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1825
TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1925
COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1625
REPAIR ANDOVERHAUL OFROTORCRAFT983085 A KEY PROVIDER OF ESSENTIALHELICOPTER LIFE983085CYCLE SUPPORT
KONGSBERG performs services on key dynamic helicoptercomponents Main Tail and Intermediate Gear Boxes Mainand Tail Rotor Heads and Drive Shafts
KONGSBERG has carried out work on the followingcomponents for Agusta Westland Sea King and LynxMain Gear Box Main Rotor Head Intermediate Gear Box
Tail Gear Box Tail Rotor Head and Drive Shafts
Previously KONGSBERG has participated in the F-16 programwith production and maintenance of Adapter Penguin MK3missile Air Circulation Equipment (Cooling Turbine)Brake amp Anti-Skid System KONGSBERG has also beeninvolved in maintenance of the following artilleryL70 Anti-Aircraft Gun and 20 mm Anti-Aircraft Gun
KONGSBERG has today ongoing contracted serviceson NH-90 Sea King SAR and Lynx helicopters and willbe a main contributor for years to come
KONGSBERG HAS FOR MORE THAN 25YEARS PERFORMED OVERHAUL AND
REPAIRS ON THE SEA KING SAR AND LYNXAIRCRAFT DYNAMIC COMPONENTS WITH
LICENSE FROM AGUSTA WESTLAND
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1725
bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1825
TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1925
COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1725
bull Local repair by handbull Repairs of components according to
approved proceduresbull Installation of oversize linersbull Introduction of modifications after
written proceduresbull Restoration of surface protection
as Cadmium plating chromicacid treatment for magnesium chromate conversion coating
bull Stopping and removal of corrosionbull Painting
REWORK ANDMODIFICATIONSOF COMPONENTS3
bull All hoses and tubes arepressure tested
bull All valves are tested inaccordance with their manuals
bull Components are testet for cor rect torque flow and oil leakagebull Main components such as the
main gearbox are tested in aspecial testbench simulatingoperating conditions
ASSEMBLY AND TEST5
bull Local Repair by handbull Local repair of surface treatmentbull Use of special tools during assembly
ASSEMBLY PROCESS4
bull All components should be cleanedbull Visual inspectionbull Dimensional inspectionbull Special inspection due to
experience or incidentsbull NDT (non destructive test)
Magnetic particle and fluorescentpenetrant inspectionEddy current and X-ray inspection
bull Release of work
INSPECTION2
bull The component is dismantled downto all the assembled pieces
bull Cleaned for dirt and oil to allowfor inspection
bull Removal of paint where NDT is requiredbull Trained inspectors with long
experience will go through allingoing parts to discover anyabnormallity
PRE983085INSPECTIONSTADIUM1
bull Incoming inspection
bull Technical documentation issue
bull Disassemblybull Inspection
bull Reassembly
bull Test bench run
bull Inspection after green run
bull Oil leak test and preservation
bull Painting
bull Issue of acceptancedocumentation (statement ofmaintenance conformity)
bull Delivery
MAIN PHASES
REPAIR AND OVERHAULOF DYNAMIC COMPONENTS
FOR HELICOPTERS IN CIVIL
AND MILITARY SERVICE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1825
TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1925
COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1825
TOTAL QUALITYMANAGEMENT983085FOR BEST SAFETY QUALITY AND ON983085TIME PERFORMANCE
CONTINUOUS IMPROVEMENTSKONGSBERG never wants to settle for second best We willalways strive to improve through continuous focus on ldquoCOL-LABORATIONrdquo building efficient teams and work processesthroughout our organization and manufacturing facility
RISK MANAGEMENTMinimizing and preventing risk is key to how we do ourbusiness and is a clear focus in cooperation with ourinternational suppliers and customers
INSP ECTIO NProducts are inspected as they are manufactured
The inspection is performed as a natural part of ourmanufacturing process Advanced equipment like theCMM and multi-axis NDT is used when manual methodsare inadequate A first article inspection (FAI) is performedin accordance with AS9102
FODFor KONGSBERG prevention of FOD (Foreign Object DebrisDamage) in our facility and in our products is of vital impor-tance The manufacturing facility is divided into FOD areaseach responsible for daily monitoring and follow-up of theirown progress with regards to FOD prevention
LESSONS LEARNEDRoot cause analysis and lessons learned methodology is anatural part of how we work and seek to learn and improveour skills products and services
ATTITUDE AND SKILLSldquoDEDICATIONrdquoat every level and through each worker ishow we achieve our strict product requirements and buildstep-by-step a sustainable performance platform to ensureour present and future business success
Our employees are trained in all aspects of their work fromskills and methods to awareness and problem-solvingIn 2011 twenty-tree lean-six-sigma greenbelts wereeducated in lean principles
KONGSBERG MANAGEMENT SYSTEMOur Quality System is certified in accordance
to the following standardsbull ISO 9001bull ENAS 9100bull ISO 14001bull AQAP 21102210
KONGSBERG also certifies personnel in accordance to inter-national standards Examples are Non-Destructive Testingpersonnel certified in accordance to EN 473NORDTESTandor NAS 410EN 4179
Inspection personnel is trained inthe following standardsbull NS-ISO 8015bull ASME Y145-2009
KONGSBERG PRODUCTSCANNOT FAIL IN SERVICE983085 OPERATING ON THE SEA BEDON MILITARY VEHICLESAND AIRCRAFT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1925
COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 1925
COMPLEXSTRUCTURES
FOR EXTREME USE
STATE983085OF983085THE983085ARTMANUFACTURING983085 M A J O R V O L U M E S A N D C O M P L E X P R O D U C T I O N S E R I E S
ERP-LN and ENOVIA (PDM)KONGSBERG uses the Enterprise Resource Planning systemERP-LN and the Product Data Management system (PDM)ENOVIA as our backbone manufacturing system Our integratedERP-LN system includes quoting planning scheduling inventorymanagement and material management
MANUFACTURING EXECUTION SYSTEMSAP-ME AND SPCProcesses are developed and implemented in SAP-ME (MES)All process descriptions are in English digital and withhyperlinks to ENOVIA to ensure configuration control WithSAP-ME we are able use the Statistical Process Control (SPC)feature for monitoring processes during operation Processcapability data can be collected on processes affecting KCs
UNIT TRACKINGAll production reports and COCs are filed as electronicbuy-off packages These can be sent directly tocustomer through an as-built structure
LOB AND PERFORMANCE METRICSWe operate an efficient schedule and progress control andreporting system using an automated Line of Balance (LOB)from our ERP-LN system Daily updated LOB and metricsreports are visualized on status boards in production
CAPACITY ANALYSIS AND IMS
The Shop Floor Control function in ERP-LN is used for nearfuture analysis based on sales orders A supporting in-housedatabase offers longer-term simulations of required resourcesand procurements related to capital equipment
These analyses form the basis for our IntegratedManufacturing Schedule (IMS) visualizing desired capabilitieslearning curves and need for future capital investments
IMPROVEIMPROVE is KONGSBERGrsquos overall quality managementsystem for handling internal non-conformance processesproviding mitigating plans reports and statistics IMPROVEis also used by our Procurement Department for risk assess-ments of sub-suppliers with subsequent mitigation plans
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2025
DRIVING RESULTS983085THROUGH A METRIC ANDPERFORMANCE983085BASED CULTURE
KONGSBERG drives results through a metric andperformance-based culture improved through lean six sigma
methodology integration and standardization Key focus is onreducing process lead time quality defects cost and invested capital
Lean Six Sigma is used by our key international customers NGC andLMA and we have 20 trained Lean Six Sigma Green Belts working on
our international contractual programs A master black belt issupporting on-going work
Value Stream Mapping is an integral part of our continious improvementwork and provides product and process control throughout our value chain
KONGSBERG BUSINESS MANAGEMENT SYSTEMKONGSBERGs overall business management system is mandatory to
all business units including KONGSBERG Aerostructures Designed to manageperformance and achieve business goals through highly professional
product and project management
HSE MANAGEMENT KONGSBERG focuses strongly on
bull Systematic approach to HSEbull Promoting job satisfaction
bull Good and safe working environmentbull Maintaining low level of sick leaves
bull Avoiding injuries and accidentsbull Analyzing and controlling risks and threats
EXTREMECONDITIONSHUMANPERFORMANCE
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2125
The key to KONGSBERGS success lies in the combinationof good leadership and dedicated skilled co-workersKONGSBERG focuses strongly on post-education andin-service training for our experienced employeesKONGSBERG is seen as an attractive workplace and wasin 2011 rated the 5th most desired work place for youngengineers in Norway
Apprenticeship is a clear focus at KONGSBERG and is offered in
cooperation with Kongsberg Technology Training Center(K-Tech) at the heart of Kongsberg Technology Park K-Tech is a joint ownership between KONGSBERGDefence amp Aerospace (KDA) FMC Technologies and VolvoAero Norge AS and offers professional industrial technologytraining Areas of apprenticeship arebull Automationbull CNC machiningbull Industrial mechanics (Industrimekaniker)bull Assembly (Industrimontoslashr)bull Tooling (Verktoslashymaker)bull Weldingbull Logisticsbull IKT (IKT servicefag)bull Compositesbull Dimension control (Dimensjonskontroll)
Overall 18 apprenticeships was successfully completed atKONGSBERG Aerostructures during 2011 The first personobtaining a polymer composite certificate in Norwaycompleted her apprenticeship with KONGSBERGAerostructures in 2011
KONGSBERG offers project professional certification andtraining for project and line managers and project team members
The KONGSBERG Leadership Model (leadershipKongsberg)is built up around four principlesbull Pursue ambitious goalsbull Promote improvement processesbull Set a good examplebull Ensure development through challenges
COMPETENTMANAGERS PROGRAM983085 AND PRODUCTION TEAMS983085 K E Y T O K O NG S B E R G S S U C C E S S
Martin Munkeby (21) came to KONGSBERG for his apprenticeship in 2008and completed his examination as CNC machinist in 2010 He was appointeda CNC programmer in the beginning of 2011 after his silver medal in theNorwegian National WorldSkills event He also successfully participatedin the world championship achieving 11th positionndash a very strongperformance for a young Norwegian apprentice
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2225
WHAT WE START WE FINISH WE DO NOT GIVE IN
KONGSBERG Aerostructuresrsquosuccess is founded on a 200 year long KONGSBERG history ofworld-class achievements gained through a relentless quest for world-class innovationscontinuous hard work and unmistakable head-strong determinationKONGSBERG Aerostructures will always strive for world-class performance and is committedto ensuring the future success of our customers and partners operating in global highlycompetitive and extremely challenging industries from Subsea to Aerospace
We will relentlessly pursue innovation and new solutions always having quality safety andsecurity in mind aspiring to achieve sustainable development with a good balance betweenfinancial results and corporate social and environmental responsibilities
KONGSBERG Aerostructures is committed to always be in the forefront and always remainworld-class through our people technology and continuous dedication Our four KONGSBERGcorporate values define who we are and how we do our business Innovative ReliableDetermined and Collaborative What we start we finish We do not give in
Terje BraringthenExecutive Vice-PresidentKONGSBERG Aerostructures
Behavior in business matters is governed byKONGSBERGrsquos Code of Ethics Business Conduct and
Compliance together with internal procedures andrelevant laws and regulations
SECUR ITY A T A R SENA LET
All KONGSBERG Aerostructures employees must complete atraining session with regards to our facility Arsenaletlsquos Security
Plan Security Instruction INS0096 and ITAR regulations
Persons entering Arsenalet must carry a visible valididentification card Photographing including use of cellphone cameras is forbidden Food drinks or tobacco isprohibited in the workshops throughout the facility
KO NGSBER G CO R P O R A TE CO MP LIA NCE
Compliance with the Code of Ethics i s mandatory and allemployees and representatives of KONGSBERG are requiredto pertain to the Codersquos provisions
KO NGSBER G CO R P O R A TE SO CIA L R ESP O NSIBILITY 983080CSR 983081
KONGSBERG aspires to achieve sustainable development to strikea good balance between financial results and corporate social and
environmental responsibility The value created will accrue toowners stakeholders and society-at-large
KO NGSBER G HEA LTH SA F ETY A ND ENV IR O NMENT
KONGSBERG is a responsible organization characterized byintegrity and concern for health safety and the environment
BUSINESS CONDUCT
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2325
N O TE SN OT E S
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2425
NOTES
KONGSBERG is an international corporation with strong
Norwegian roots Collaboration with our customers partners andsuppliers and a commitment to understand the context where
our technology is applied are important driving forces behind
the corporationrsquos international development and growth
Denmark Sweden
India (2)
StJ ohnrsquos (Canada)
Antarctica
Kuwait
United ArabEmirates
Finland
Australia
Ireland
Algeria
Salt LakeCity (USA)
Vancouver (Canada)
Lynwood (USA)
Dalian (China)
Zhenjiang(China)
Norway (15)
Main OfficeinKongsberg
Kongsberg AskerBergenBillingstadHortenKjellerKristiansandOsloSandeordSandvikaStavangerStjoslashrdalSvalbardTromsoslashTrondheim
Pocasset (USA)
Johnstown(USA)
Venezuela
Svalbard(Spitsbergen)
Washington (USA)Mount Arlington (USA)
West Mystic (USA)
LongIsland(USA)
Brazil
United Kingdom (8)
South Africa
Nigeria
Spain
Mexico
New Orleans (USA)
Houston (USA)
London (Canada)Poland (2)
NetherlandsGermany
Hungary
Russia
Italy
Greece
Halifax (Canada)Ottawa (Canada)
Shanghai (China)
South Korea (5)
Guangzhou (China)
Singapore(2)
Saudi Arabia
WORLDWIDEOPERATIONS
7242019 Aero Structure
httpslidepdfcomreaderfullaero-structure 2525
WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22
7242019 Aero Structure
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WORLD CLASS- through people technology and dedication
Headquarters
Kirkegaardsveien 45POBox 1003N-3601 KongsbergNorway
Tele phone+47 32 28 82 00
Site Address
AEROSTRUCTURESBergmannsveien 241N-3615 KongsbergNorway
Telephone+47 920 600 22