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Welcome to GKN-Advanced Composite Structures November 7,2014

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Page 1: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

Welcome to GKN-Advanced Composite Structures November 7,2014

Page 2: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 3: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 4: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

$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

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Page 5: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

Market

Business Mix

Sector

Customer Base

GKN Aerospace – Markets and Customers

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Page 6: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 7: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 8: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

GKN Aerostructures North America Leadership Team

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Page 9: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 10: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 11: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 12: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

Our ACS Safety Guidelines:

X

Eye and Footwear PPE

Gloves and Hearing PPE

Stop, Look, Listen

Use Pedestrian Doors

100% of Factory

As applicable in designated areas

100% of Factory

100% of Factory

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Page 13: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

GKN ACS - Leadership Team

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Page 14: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 15: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 16: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 17: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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 %

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Page 18: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 19: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

GKN ACS - Core Competencies Alabama Design Engineering center launch - 2013

Design and analysis and design for manufacture (DFM) for customers

Initial projects underway

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Page 20: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 21: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 22: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 23: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 24: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

Two CNC Honeycomb machining

GFM single cut tables CNC machining of parts

GKN ACS - Manufacturing Facilities

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Page 25: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 26: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

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

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Page 27: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

Moving forward with the strategic agenda – GKN ACS

Sustain above market growth

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

Operational excellence

Technology driving margin

Leverage global footprint

Lead in chosen markets

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

Out of Autoclave technologies Flexible manufacturing systems

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

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Page 28: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

GKN Advanced Composite Structures

It’s All About The People!!!

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Page 29: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome
Page 30: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

The Lean Enterprise Model

GKN Vision

(PE)

(PrE) (BPE)

Page 31: Welcome to GKN-Advanced Composite Structures - · PDF file · 2016-11-262005 761 . Employees . $150 . Million . 2006 . 840 ... composite structure Product Design Center ... Welcome

Common Language – With Focus Area’s