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Page 1: Aero Structure

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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

Page 2: Aero Structure

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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

Page 3: Aero Structure

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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

Page 4: Aero Structure

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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

Page 5: Aero Structure

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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

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

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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

Page 10: Aero Structure

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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

7242019 Aero Structure

httpslidepdfcomreaderfullaero-structure 1125

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)

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

Page 11: Aero Structure

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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)

7242019 Aero Structure

httpslidepdfcomreaderfullaero-structure 1325

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httpslidepdfcomreaderfullaero-structure 1425

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

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

Page 12: Aero Structure

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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)

7242019 Aero Structure

httpslidepdfcomreaderfullaero-structure 1325

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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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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

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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

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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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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

Page 13: 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

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

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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

Page 14: Aero Structure

7242019 Aero Structure

httpslidepdfcomreaderfullaero-structure 1425

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

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

Page 15: Aero Structure

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

Page 16: Aero Structure

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

Page 17: Aero Structure

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

Page 18: Aero Structure

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

Page 19: Aero Structure

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

Page 20: Aero Structure

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

Page 21: Aero Structure

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

Page 22: Aero Structure

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

Page 23: Aero Structure

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

Page 24: Aero Structure

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

Page 25: Aero Structure

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