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Pratt & Whitney AutoAirPratt & Whitney AutoAir

August 2010

This document is the property of United Technologies Corporation (UTC). You may not possess, use, copy or disclose this document or any information in it, for any purpose, includingwithout limitation to design, manufacture, or repair parts, or obtain FAA or other government approval to do so, without UTC's express written permission. Neither receipt norpossession of this document alone, from any source, constitutes such permission. Possession, use, copying or disclosure by anyone without UTC's express written permission is notauthorized and may result in criminal and/or civil liability.”WARNING -- This document contains technical data the export of which is or may be restricted by the Export Administration Act and the Export Administration Regulations (EAR), 15C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export, reexport, transfer or re-transfer of this technical data to any other company, entity, person, or destination,or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without prior written approval from P&W and authorization underapplicable export control laws.

EAR Export Classification: ECCN 9E991.

2

PWAA Organization

Operations Manager

Andy Storm

Sales

Claudia Carter

Quality Manager

Talha Rathur

Materials Manager

Jason Szalanski

ManufacturingEngineeringManager

Gary Franck

General Manager

Steve Foster

Human ResourcesManager

Michelle Blakely

Controller

Mike Friar

Customer ServiceManager

Jim McCoy

Thrust Reverser Team

Research &DevelopmentEngineeringManager

Gary Wigell

Customer Service

Rob Koresky

Leadership Team

Cell Leader

Don Reynolds

Cell Engineer

Colby Page

Quality Engineer

Don Reeves

Sales

Brian Garceau

“P&W PROPRIETARY - Subject to the restriction on the title or cover page.”

3

Organization OverviewStatistics

Structure

4 Plants - 159,000 ft2

204 Employees – 65 Salary, 139 Hourly

ACE Site Silver

Plant 1

Plant 3

Plant 2

LansingCampus

SunfieldCampus

Plant 4


Incorporated in 1956

Acquired by Pratt & Whitney as part of theCADE Industries purchase in 1999

4 Divisions: OEM, MRO, Thrust Reversers &Ground Test Nacelles

PWC19.3%

OEMROOEM Capability MRO Flexibility

For the life of your engine

TM



TM

44

Composite Product Divisions

• Driven by repair development

• Positioned around EC network

• Leader in A330-300 (PW4168) repairs

• Targeted growth in V2500 market

• Focused on UTC subsidiaries• ROS threshold drives OEM strategy

• Industry leader in quality & durability

• Supplier to all major engine OEMs

RepairDesign Build Spares RDE

OEM

MRO

TR

TEST


5

CUSTOMERSCUSTOMERS

EMPLOYEESEMPLOYEES

QUALITYQUALITY

Technology & InnovationDelightDelight

CustomersCustomers

FINANCIALFINANCIAL

P&W AutoAir - 2010 Roadmap

Preserve the Core and Stimulate GrowthPreserve the Core and Stimulate Growth

Unm

atchedEH&SPerformance

HighestB

usinessEthics

Always

Perfect Quality Wins Customer Loyalty

Customer Scorecard > 6.0; Provider of Choice

Employee Engagement over 65% survey favorability

ACE Gold & Supplier Gold value streams drive perfect Quality

Deliver financial plan commitments

EH&S• Achieve EH&S plan• Energize People Based Safety (PBS) programEmployee• Acquire, develop & retain talent to grow AutoAir• Drive integrity and meet all UTC ethics compliance goals• Execute key employee communications• Implement a sustainable training program for salary and hourlyFinance

• Execute a robust Manufacturing Engineering and Operations processreview strategy to expand margins and drive quality targets

• Implement cell productivity measures with 10% improvement• Explore global outsourcing of SAP report generation and delivery

• Develop creative solutions and cost reduction initiatives to competemore effectively on A330 Thrust Reverser campaigns

Customer• Continue > 95% OTD performance• Achieve consistent TR TAT of 60 days

• Successfully complete Test Nacelle design and First Engine To Test(FETT) for PW1217Gand PW1524G programs

• Develop and implement a One Company OEMRO strategy for theNGPF program

• Grow OEMRO market share and expand field service offerings tosupport 2012 and beyond

• Implement OneAero customer service platform• Establish a world class Composite Incubator to drive 2X growthQuality

• Achieve ACE Site Gold through robust tool usage and metricsmanagement

• Develop and certify a robust quality clinic process

66

Control Tower


7

Customer & Sales Overview


ASIA-PACIFICEagle Services Asia (13%)

Thai Airways (8%)

Malaysia Airlines (3%)

Korean Airlines (1%)

China Airlines (TEST & MRO) (1%)

GE Malaysia (1%)

Christchurch (1%)

Japan Airlines (1%)

TAM (14%)

P&W - Canada (11%)

P&W/PDC (10%)

PWEH GTF (9%)

GP&W Cheshire (5%)

CEC (TEST & MRO (3%)

Standard Aero (3%)

United Airlines (2.5%)

EUROPE/M.E.Lufthansa (1%)

Rolls-Royce (1%)

HiFly (1%)

LTU (Air Berlin) (1%)

H+S Aviation (1%)

Americas

68%

Europe

4%

Asia

28%

Region YTD June 2010 Sales

Test

22%OEM

19%

MRO Core

26%Thrust Reversers

33%

Product YTD June 2010 Sales

THE AMERICAS

87 Total CustomersTest

13%OEM

31%

MRO Core

36%Thrust Reversers

20%

Product 2009 Sales

Americas

68% Europe

7%

Asia

25%

Region 2009 Sales

88

Quality

COPQ: .43% YTD (Jan to July)

Escapes: 3 YTD (0 for United)

Audits: CASE, No majors.

Certified: AS9100FAA FAR-145EASACAAC CCAR-145 R3CAAVTHAILAND DCA

9

Fan Blade Fairing Journey Results

10

PW2000 Case Kaizen Event

KaizenNewspaper

Products

Optimize the OEM productionand MRO repair of the Cases,Liners and Fairing product linesto increase productivity, improveEH&S and reduce cost of poorquality.

Mission Statement

Current State

Cell Layout

Paper Doll Model

Blue Book Standard Work

Reduction of600 sq ft

11

Recv &Uncreated

-Hoist-Tools

InnerInsp area

(Part on Fixture)

OuterInsp area

(Part on Fixture)

Insp & DispositionDesk/Computer

DisassembleArea

-Fixtures-Drills-Tools

-Work bench

OutflowtoClean

Scheduleboard

Box forShipping

-Hoist-Tools

Start

Finish

OutflowtoSub

contract

Scheduleboard

Recv &Uncrate

-Hoist-Tools

InnerInsp area

(Part on Fixture)

OuterInsp area

(Part on Fixture)

Insp of Sub contractDesk/Computer

AssembleArea

-Fixtures-Drills-Tools

-Work bench-Hoist

Final Insp &8130

Final InspDesk/Computer

Create &Ship

-Hoist-Tools

Future Nozzle Cell

10’ X 10’ 3’ X 10’

Old Cell Layout

New Cell Layout

• Cell Layout•Problem No cell layout•Solution Developed cell LayoutImplementing in 3Q 2010

•Old Nozzle Cart•Problem Hard to move parts•Carpet got Dirty•Solution Had vendor developa cart that is easy to moveand stays clean

•Rivet removal•Problem Hand drilling notrepeatable•Solution Controlled Feeddrilling process implementingin Q3 2010

Old Nozzle Cart

New Nozzle CartNew Controlled Drilling

Process

1212


13

Composite Product Grouping


14

Composites Incubator – The Genesis


ProcessVillage

CellularManufacturing

DevelopmentCell

• Developmentperformed inmanufacturingcell

• Developmentwork done byManufacturingEngineer

• Product movedfrom process toprocess

• Developmentperformed inmanufacturingcell impactedOTD and TAT ofproduction parts

• ManufacturingEngineersfocused on cellefficiencies

• Developmentefforts wereconsidered adistraction by cell

• Developmentcell dedicated tonew product &process created

• DedicatedDevelopmentEngineers

• DedicatedSkilled Hourlyteam

• Space createdby Kaizen events

• FlexibleDevelopment celllayout

• Developmentwork done inconjunction withtarget cell

• Developmentwork done withP&W UnitEngineering onsite

2000 2005 2010 Future

15

Product Life Cycle & EngineeringDesign &

Development Manufacturing SparesSupport

RepairDevelopment Repair

OEM

MRO

Test

• Already contracted for $8.5M in Customers Paid NRE For BA “C” Series AndMRJ Test and FTB Nacelle System Development

• Over 100 Composite Repairs developed annually

• Working With CSMC on BA “C” Series And MRJ OEM Component Development

• Use Of OEM Development Work To Develop Repairs For BA “C” Series AndMRJ Engine Components

COMPOSITES INCUBATORDEVELOPMENT RECIPIENTS


1616

Composites Incubator – Flexible Manufacturing Cell


• Staffed with Senior Engineers and Skilled Hourly Employees (Article 17.7 of IAM Contract)• Dedicated to Developing Product And Processes• No Production Interruptions or Resource Competition• Full Array Of Movable Work Stations, Clean Room, Etc.• Overhead Carry System For Power, Air and Vacuum Drops• 1850 Square Feet of Manufacturing Area• 5-Axis Machine Center, 5’x7’ Clave in cell

1717

31

V2500 Panel Repair

Cost

Sales

REATech Data

Year5 Total

Part Number(s)

Customer(s)

Target Price

Volume

Year4

Target DateTarget Cell

MarginATA

Year3

Year2

Year1

PWAA

Rev.Engr.Comp.

Sales

MarketPlanComp.

PWAA

Router& BOMComp.

PWAA

Tooling&

FixtureAvail.

RSA

RSAComp.

Start

Name

Due

End

PWAARSAGSEPWAALegalPWAAPWAAPWAASalesGroup

1st PartComp.

RSAProg.Plan

TechDataAvail.

DesignReview(R3)Comp.

LegalReviewComp.

HeadsAvail.

AssetAvail.

ProjectLaunch(R2)Comp.

NeedID’dMilestone

Priority: 2OEM MRO TR’s Test Unit Funded Capital FundedGSE Funded

38

V2500 Splitter Repair

Cost

Sales

REATech Data

Year5 Total

Part Number(s)

Customer(s)

Target Price

Volume

Year4


MarginATA

Year3

Year2

Year1

PWAA

Rev.Engr.Comp.

Sales

MarketPlanComp.

PWAA

Router& BOMComp.

PWAA

Tooling&

FixtureAvail.

RSA

RSAComp.

Start

Name

Due

End


1st PartComp.

RSAProg.Plan

TechDataAvail.


LegalReviewComp.

HeadsAvail.

AssetAvail.


NeedID’dMilestone


Composites Incubator – V2500 Engine MRO

Project TaskApproval R2 Dev

HardwareScan &Model

PanelData Tol Study REDA

ApproveBushingData Tol Study REDA

Approve Matl Anal SampleTool

PartSample Part Test DDM

Create Structures ASR PatentSearch R3 EA

Approve RSA Part Tool Ops Shts RQR R4

A/O Panel 5/9/08 8/25/09 8/26/09 10/6/10 5/4/10 3/1/10 7/30/10 7/23/10 7/30/10 8/16/10 3/10/10 9/8/10 9/23/10 10/7/10 10/21/10 10/21/10 11/4/10 11/24/10 12/1/10 12/8/10 12/17/10 11/5/10 12/20/10 1/31/11 2/14/11Seal 10/10/08 12/15/08 1/12/09 N/A 5/6/09 5/22/09 6/5/09 N/A N/A 6/9/09 7/9/09 9/7/09 9/9/09 10/10/09 12/15/09 1/30/10 N/A 2/9/10 1/30/10 2/10/10 8/27/10 N/A 8/6/10 8/27/10 9/1/10Splitter 5/6/10 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 5/18/10 5/26/10 N/A N/A N/A 5/28/10 N/A 6/5/10 6/21/10 N/A N/A

32

V2500 Seal Repair

Cost

Sales

REATech Data

Year5 Total

Part Number(s)

Customer(s)

Target Price

Volume

Year4


MarginATA

Year3

Year2

Year1

PWAA

Rev.Engr.Comp.

Sales

MarketPlanComp.

PWAA

Router& BOMComp.

PWAA

Tooling&

FixtureAvail.

RSA

RSAComp.

Start

Name

Due

End


1st PartComp.

RSAProg.Plan

TechDataAvail.


LegalReviewComp.

HeadsAvail.

AssetAvail.


NeedID’dMilestone


• Seal Repair For CEC/UAL to be ready on September 1st , Hundreds of parts ready to induct

• A/O Panel scheduled to be repair ready in February 2011, working with GSE to pull back into 2010

• Splitter Repair complete


1818

30

GTF Fan Blade

Cost

Sales

REATech Data

Year5 Total

Part Number(s)

Customer(s)

Target Price

Volume

Year4


MarginATA

Year3

Year2

Year1

PWAA

Rev.Engr.Comp.

Sales

MarketPlanComp.

PWAA

Router& BOMComp.

PWAA

Tooling&

FixtureAvail.

RSA

RSAComp.

Start

Name

Due

End


1st PartComp.

RSAProg.Plan

TechDataAvail.


LegalReviewComp.

HeadsAvail.

AssetAvail.


NeedID’dMilestone


34

GTF Fan Case Liners and Bond

Cost

Sales

REATech Data

Year5 Total

Part Number(s)

Customer(s)

Target Price

Volume

Year4


MarginATA

Year3

Year2

Year1

PWAA

Rev.Engr.Comp.

Sales

MarketPlanComp.

PWAA

Router& BOMComp.

PWAA

Tooling&

FixtureAvail.

RSA

RSAComp.

Start

Name

Due

End


1st PartComp.

RSAProg.Plan

TechDataAvail.


LegalReviewComp.

HeadsAvail.

AssetAvail.


NeedID’dMilestone


Fwd Liner

Ice Liner

Rubstrips

Aft Liner

Case Bont

Composites Incubator – GTF OEM / MRO

• 18 blades per engine set, 340 engines per year, 6000+ blades Per year, 20 year product cycle

• Guaranteed MRO work, Leading edge, Erosion Coating and Wear Pads (GE90 Fan Blade Model)

• Tech Data from OEM manufacturing and capital equipment will be key barriers to entry into the MRO market

Project Need ID'dProjectLaunch

HeadsAvail Eng. Req.

DesignReviewComp.

Tooling &FixtureAvail.

Router /BOMComp.

First partComp.

FirstArticleInsp.

GTF Fan Blade 2009 Jan-10 Feb-10 Mar-10 Mar-10 Jun-10 Feb-10 Feb-10 Feb-10GTF Fan Case 2009 Feb-10 Mar-10 Mar-10 Jun-10 Jul-10 Jul-10 Aug-10 Aug-10GTF FWD Liner 2009 Feb-10 Mar-10 Mar-10 Jun-10 Jul-10 Jul-10 Aug-10 Aug-10GTF AFT Liner 2009 Jan-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10GTF Ice Liner 2009 Jan-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10 Feb-10


1919

Composites Incubator – V2500 Thrust Reverser

Project TaskApproval R2 Dev

HardwareScan &Model

SurfaceData

InterfaceData

REDAApprove Matl Anal Sample

ToolPart

Sample Part Test DDMCreate Structures ASR Patent

Search R3 EAApprove RSA Part Tool Ops Shts RQR R4

V2500-A5 T/R 5/5/10 9/15/10 6/25/10 9/1/10 10/1/10 10/1/10 10/21/10 9/15/10 9/30/10 10/15/10 10/30/10 11/7/10 12/15/10 12/31/10 N/A 1/7/11 1/15/11 1/30/11 1/30/11 1/15/11 2/15/11 2/30/11

• Acquired Left Hand Door, still needs to have Overhaul tag before Reverse Engineering can begin per RESW

• Right Hand Door due in at the end of August, Structural Repairs are consistent door to door

• Pushing to spend the $800k tooling budget in 2010


20

REPAIR DEVELOPMENT

MATERIALS RESEARCH AND DEVELOPMENT

COMPOSITE LAMINATE AND HYBRID METAL-COMPOSITEDESIGN

RE-DESIGN OF METALLIC COMPONENTS INTO COMPOSITES

STATIC AND DYNAMIC STRUCTURAL ANALYSIS

FINITE ELEMENT ANALYSIS

MODAL & FREQUENCY

LAMINATE ANALYSIS

PROTOTYPE DEVELOPMENT

FAILURE ANALYSIS & DISTRESS MODE STUDIES

ACOUSTIC DESIGN AND EVALUATION


20

Engineering Capabilities

21

CAD•CATIA

•PRO/ENGINEER

•UNIGRAPHICS

•AUTOCAD

CAM•PRO/MANUFACTURE

•SMARTCAM

•ICAM

CAE•COSMOS/M

•MECHANICA

•MSC NASTRAN

•GEOMAGIC


21

Computational Capability

22

FROM EXISTING PART TO DIGITAL SURFACEPratt & Whitney AutoAir has both LASER and probe digitizing capabilitythat allows the product definition to be captured as a digital surface. Thesoftware can analyze the data from multiple parts and determine anominal dimension and a tolerance band on features for future repairs.


22

Reverse Engineering

23

FINITE ELEMENT ANALYSISStatic and dynamic analysis is performed on structures in the “as designed” state and “as repaired”state. The results are compared to show compliance with the applicable FAR’s. The part metrology,material and construction are determined by reverse engineering.


23

Composites Structures Validation

24

VALIDATION &VERIFICATION

Unit 905

45.97104

212.2911

126.1052

0

20

40

60

80

100

120

140

0 50 100 150 200 250 300 350

Frequency (Hz)

G(peak)

0

20

40

60

80

100

120

140

G(peak)

Accelerometer 1Accelerometer 2Accelerometer 3Controller feedback

VIBRATION OR MODAL TESTINGVibration testing is the process of applying a controlled amount of vibration to a structure to determinethe frequency response function and/or modal characteristics. Vibratory input is provided by meansof an electro-dynamic shaker mechanism capable of producing a forcing function sufficient to excitethe normal modes of the structure.

A nacelle assembly has specific frequency characteristics that relate directly to the stiffness / massrelation and connectivity of the structure. This technique makes it possible to compare and verify arepaired nacelle assembly with the systems specific frequency characteristics.


24

Composites Structures Verification

25

Non-Destructive Evaluation With Laser Shearography• Determines Size and Location of Disbonds in Honeycomb Sandwich Panels• Determines Size and Location of Delamination in Laminated Structures• Determines Size, Location & Number of Inclusions in Molded Panels & Laminates• Updated high resolution equipment on order and due in house on October 15th, 2010

NDI of Fan Case Abradable Laser Unit in Vacuum Chamber


25

Laser Shearography

26

Rayl Testing Device (Raylometer) for Measuringthe Pressure Drop Across an Acoustic Face

Zonic AIMSIII Testing Device for DeterminingAcoustic Impedance and Reactance.


26

Acoustic Evaluation

27

ACE Journey to SILVERSILVER

• First Units Transferred from HAC• Originally Located in Plant 2• Transactional Customers• Minimal WIP and Capacity• 400+ Day TAT

• Transferred to Plant 3• Established Contractual LTA’s with Customers• Maximized Capacity to 48 Units per Shift• 100+ Day TAT

2015

• ACE Silver• TRx Standard Work• Gated Flow

• Future Plant Layout• Plt.1&3 Consolidation

Qualifying

2004

2007

2008

2009

Bronze

Silver

Gold

Qualifying

2009

2010

Bronze

Silver

Gold

•Test 6S – Silver

2000

28

Before ACE

2929

Thrust Reverser 2010 YTD Performance

30

PWC19.3%



TM

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