welcome to gkn-advanced composite structures - · pdf file · 2016-11-262005 761 ....
TRANSCRIPT
Welcome to GKN-Advanced Composite Structures November 7,2014
Each division is a market leader, outperforming its markets, giving unrivalled expertise and experience in delivering cutting-edge technology and engineering to our global customers
GKN Driveline A world leading supplier of automotive driveline systems and solutions, including all-wheel drive.
GKN Powder Metallurgy The world’s largest manufacturer of sintered components, predominantly to the automotive sector.
GKN Aerospace A leading Tier 1 supplier to the global aviation industry focused on aerostructures, engine systems and products and specialty products.
GKN Land Systems A leading supplier of technology-differentiated power management solutions and services to the agricultural, construction, industrial and mining sectors.
2013 - Sales By Division ~ $12B
$5,397M
$3,544M
$1420M
$1473M
$164M
GKN has four operating divisions
GKN plc
2
Andrew Harvey SVP Human Resources
Mike McCann CEO Aerospace Engine Systems
Tom Battaglia SVP GKN
Aerospace NA & GKN USA
Political Affairs
Nick Waters Chief Financial
Officer
Rich Oldfield Technical
Director
Ernie Peake SVP
Commercial
Neil McManus CEO
Aerospace Europe
Rob Soen SVP
Supply Chain Management
Daniele Cagnatel President & CEO
Aerostructures North America
Charles Paterson SVP Business
Development & Strategy
Kevin Cummings President & CEO GKN Aerospace
Marcus Bryson President &
Chief Executive Officer Aerospace and Land Systems
GKN Aerospace – Executive Committee
3
$3.5 billion International Aerospace enterprise 12,000 people ▪ 35 sites ▪ 8 countries – One GKN Kevin Cummings
CEO GKN Aerospace
Daniele Cagnatel
GKN Aerospace Aerostructures North America
Neil McManus
GKN Aerospace Europe and Special Products Group
Mike McCann
GKN Aerospace Engine Systems
Aerostructures North America Europe & Special Products Group Engine Systems
GKN Aerospace
4
Market
Business Mix
Sector
Customer Base
GKN Aerospace – Markets and Customers
5
Transparencies and Protection Systems
Special Products 5% of Sales 2013
Engine structures NACELLE & PYLON ENGINE SYSTEMS & SERVICES 50% of Sales 2013
Aerostructures WINGS & FUSELAGE 45% of Sales 2013
A380 Fixed Trailing Edge
A350XWB Rear Spar
B767 Winglet
J-UCAS Fuselage
B787 Floor Grid
F35 Canopy
B787 Cabin Windows
V22 Fuel Tanks
B787 Anti-icing System
Full Engine MRO and support
Ariane 5 Exhaust nozzle
A400M Engine Intake
B747-8 Exhaust
Engine structures
Engine rotatives
GKN Aerospace – World class product portfolio
Global #1/2
Global #2
Global #3
6
Next generation composite processes Advanced metallic processes
Advanced process development
Transparencies and coatings
Future product differentiation
Future wing technologies
Advanced fuselage
Nacelle, pylon and exhaust
Engine structures
Engine rotatives
Ice protection systems
GKN Technology – Targeted Innovation
7
GKN Aerostructures North America Leadership Team
8
GKN Aerostructures North America Facility Overview
Bandy - CA Hinge center
Small Machined Ti and Al parts
ASTECH - CA
Welded honeycomb structures and fabrications
FAA-145 repair station
Mexicali Composites
Low cost composite center
St. Louis - MO
Hard Metal Machining
High Speed AL Machining
Metal Bonding
Composite Structures
Aircraft Subassembly
Tallassee - AL
Integrated composite structures & assemblies
Orangeburg - SC
Aircraft subassembly
Monitor - NY
Titanium machining technology leader
High Speed Aluminum Machining
PreMac - KS
Titanium machining & aluminum wing skin technology leader
Aircraft Subassembly GKN Aerospace North America
Headquarters TX
Aerostructure
Design Centers
MO and AL
9
Strategic Outlook – GKN ACS
GKN ALABAMA
Workforce of 962 employees Key capabilities
Mid to Complex Composite Parts
Assembly structures with increased level of automation
Development of Out of Autoclave structures (Engine Components)
Develop Engineering Composite Technology Center (Panels, Engine Components, Rotorblades)
GKN SOUTH CAROLINA
Workforce growth to 300 employees
Currently 65
Key capabilities
Manual Assembly, minimum overhead
Large structures, equipment integration
Business Jet Fuselages, Wings
OEM Floors, Nacelles, Cockpits
GKN COMPOSITES MEXICALI
Workforce growth to 200 employees
Currently 77
Key capabilities
Hand Laminates
Carbon/Kevlar/Glass Fabric
Components delivery to GKN AL
Leader in Composite Structures for the
Aircraft and Engine Markets
GKN ACS - Strategic Outlook
10
YTD ESH Status
YTD Av # EE’s
YTD LTAs
YTD Lost Days
YTD OSHA
Rec
AFR ASR Accidents DCS
Near Misses DCS
TRR
Alabama 962 0 0 12 0 0 34 23 1.5
Oburg 65 0 0 1 0 0 4 2 0
Mexicali 77 0 0 0 0 0 6 3 0
Actual 1,104 0 0 13 0 0 44 26 1.5
ACS Targets 1,156 0 0 28 0 0 All reported
All reported
2.9
All sites achieved goals for thinkSAFE-Q4 in work; RADAR’s ongoing supporting process
Alabama: Utilizing DWB campaign/Juice event, significant reduction in medical cases, Enviro-reduction in water due to cooling tower installation
Oburg: Completed 1st ESH peer audit-action plan in work, hired ESH Mgr, Targeting ISO/OHSAS 2015
MCS: Significant energy savings as a result of BPE for Autoclaves, Targeting ISO/OHSAS 2016
Improvement opportunities: Recycling, MRA Program, DoMore Program, Safety Corners
11
Our ACS Safety Guidelines:
X
Eye and Footwear PPE
Gloves and Hearing PPE
Stop, Look, Listen
Use Pedestrian Doors
100% of Factory
As applicable in designated areas
100% of Factory
100% of Factory
12
GKN ACS - Leadership Team
13
1985 Tallassee, Alabama site established
1998
1999
2003
2007
GKN acquires DOW-UT
Montgomery, Alabama site established
Significant growth of commercial projects
World’s 1st all composite fan case developed
2008
Hondajet development awarded to GKN
2012 Extended value stream grows into 2 new factories
1985 – Tallassee, AL is established by Sikorsky Aircraft to manufacture composite details for the Blackhawk helicopter 1990 – United Technologies (Sikorsky and Pratt & Whitney) form a joint venture with Dow Chemicals 1998 – GKN Westland acquires Dow-UT 1999 – Montgomery, AL is established to support the transition of assemblies from Sikorsky, CT
2000-2002 – Business volume doubles with the transfer of work from the UK including Airbus and MRAS 2003 – The site incurs significant new growth through Lockheed Martin and GE 2007 – GKN invests with GE on the worlds first all composite fan case – GEnx 2008 – GKN develops a relationship with Hondajet and is awarded the fuselage development 2009 – To increase customer satisfaction, the Tallassee operation is expanded and the Montgomery facility is closed
2010 – The Tallassee operation exceeds 1,000 employees 2012 – To support new business, 2 facilities are opened: Mexicali, Mexico and Orangeburg, South Carolina 2013 – GKN develops a relationship with Bell Helicopter and is awarded development work on the 525 Relentless
GKN-ACS Background
14
Alabama Growth
500 Employees
$85
Million
2004
631 Employees
$127 Million
2005
761 Employees
$150 Million
2006
840 Employees
$170 Million
2007
877 Employees
$214 Million
2008
970 Employees
$228 Million
2009
980 Employees
$230 Million
2010
980 Employees
$250 Million
2011
960 Employees
$276 Million
2012
529 Employees
$68
Million 2003
910 Employees
$282 Million
2013
15
Composite Engine Components GE 90 (B777) GE CF6 (B767) GE Genx-1B (B787) P&W 4000/6000 Nacelle Cowlings Blocker Doors
GKN ALABAMA / MEXICALI
GKN ALABAMA / MEXICALI
GKN ALABAMA / SC
Composite Structure Components Helicopter components and
assemblies Commercial Aircraft
Wing Tips Fixed and Movable T/E Fixed and Movable L/E Fuselage
Military Aircraft Rotor blades Integrated Assembly structures
(equipped, heater elements etc.)
Assembly Structures Honda Fuselage Honda Wings Commercial Aircraft
Assemblies Floors Winglets Racks Center Wing Box
GKN ACS - Market Segments and Key Platforms for Growth
16
Customer Relationships Customer Relationships
Expansion of content with key existing customers Capture content with targeted customers Improve customer balance to reduce market risk & increase growth potential on the Commercial Business
Strategic Objectives:
Boeing Military Lockheed Martin Bell Helicopter Hondajet
Spirit Boeing Commercial Bell
Key Strong Existing Relationships
Strategically Targeted
Airbus GE Aviation Pratt & Whitney Sikorsky
Military 2009 78% vs 2014 55 %
17
Crew Door
GKN ACS - Core Competencies
Large Composite Structures
Wing & Fuselage Composite
Bonding and Assemblies
Engine Components
Medium to Large
Assemblies
Blades
GKN ACS Build to Print
& Design and
Build
18
GKN ACS - Core Competencies Alabama Design Engineering center launch - 2013
Design and analysis and design for manufacture (DFM) for customers
Initial projects underway
19
Facility Highlights ~$280M 2013 sales
~1000 employees (non-union)
Land to expand ~325 acres
380,000 sq. ft. manufacturing floor
95,000 sq. ft. clean room
GKN ACS - Alabama
Capabilities Lay-up and assembly moderate to highly complex
composite structure
Product Design Center Tool Design and Manufacture
20
Strategic Objectives Low cost competitive supplier Provide offset support to OEM’s pursuit of Mexican
market Capacity enabler to Alabama / ANA
Product Sikorsky components successfully transferred Qualification for GE underway
Facility Highlights 80,000 sq. ft. facility, ~ 45,000 sq. ft.
occupied
12,000 sq. ft. clean room
125,000 gallons water reserve sprinkler & fire hose protection system
2,000 KVA electric substation
7 loading docks and 2 large ramps for oversize equipment
Equipment Autoclaves
10’ X 30’
500⁰F, 120 PSI
4’ X 11’
400⁰F, 100 PSI
Ultrasonic Ply Cutter
6’ x 10’ cutting bed plus 6’ x 10’ conveyor offload zone
Grieve oven
6’ x 8’ x 8’
500⁰F
GKN ACS - Mexicali
21
Orangeburg, SC Facility
150,000 Sq. Ft.
22 Acre site
Dedicated site for assembly only
Production startup Aug 1, 2012
Products:
HondaJet Fuselage and subassemblies
Honeywell engine fan duct assembly
787 Floor Beams
Orangeburg Facility
GKN ACS - Orangeburg
22
Clean rooms/ hand lay-up with Laser Ply Projection 95,000 sq. ft. Ultrasonic cutting systems (4) for composite materials
(2) Gerber tables 60 ft long ;(1) Gerber table 45 ft long (1) AGFM Ultrasonic Ply Cutter 10’ Long with conveyor offload zone
Autoclaves (10 each, largest is 15’ X 50’)
GKN ACS - Manufacturing Facilities
23
Two CNC Honeycomb machining
GFM single cut tables CNC machining of parts
GKN ACS - Manufacturing Facilities
24
Quality Inspection Equipment
5-Axis Matec C-Scan Gantry System Matec configured C-Scan 2-D Tank System Meccasonics Submersion Ultrasonic Scan Tank (4) Coordinate Measurement Machines
Fully Equipped M&P Laboratory
Calibration Laboratory
GKN ACS - Manufacturing Facilities
25
GKN Alabama - Quality Assurance
Full Quality Assurance Compliment Quality Certifications
First Article Inspection (FAI) Non Destructive Inspection
ASNT Level III Approvals
ISO9001:2008 AS9100 Rev C NADCAP NDT NADCAP Composites NADCAP Chemical Processing (Paint) United Technologies ASQR-01 Sikorsky Aircraft Airbus, GE, Lockheed Martin
ISO 14001:2004 – OHSAS 18001:2008
26
Moving forward with the strategic agenda – GKN ACS
Sustain above market growth
Composite parts and structures in aircraft are forecasted to grow at CAGR 11.2% GKN ACS well positioned to capture the growth – cost competitive, motivated workforce
Operational excellence
Technology driving margin
Leverage global footprint
Lead in chosen markets
South Carolina facility for Large Assemblies Mexicali facility for low cost hand lay-up
Out of Autoclave technologies Flexible manufacturing systems
Lean Manufacturing system implemented as the operational model Increase Revenue stream by focussing on high volume and future growth platforms (787/NEO/737M)
27
GKN Advanced Composite Structures
It’s All About The People!!!
28
The Lean Enterprise Model
GKN Vision
(PE)
(PrE) (BPE)
Common Language – With Focus Area’s