welcome to gkn- · pdf filechem-milling & aviation repair. mexicali low cost machining and...
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Welcome to GKN-ACS
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Business Portfolio & Focus in US
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ANA Headquarters TX
Mexicali Composites Low cost composite center
Alabama Integrated composite
structures & assemblies
Orangeburg - SC Aircraft subassembly
Advanced Composite Structures
St. Louis - MO Hard Metal Machining
High Speed AL Machining
Composite Structures
HLU/AFP
Aircraft Subassembly
Structures - CT RTM
Composites Development
Aerospace Structures
San Luis Potosi Low cost fan blade
machining & grinding
PreMac - KS Titanium machining &
aluminum wing skin technology leader
Aircraft Subassembly
Monitor - NY Titanium machining
technology leader
High Speed Aluminum Machining
Advanced Machine Structures
Bandy - CA Hinge center
Small Machined Ti and AL parts
ASTECH - CA Welded honeycomb
structures and fabrications
FAA-145 repair station
Chem-tronics - CA Leader in fan cases &
rings, engine structures
Chem-milling & aviation repair
Mexicali Low cost machining and
fabrication
Subassembly
Engine Products West
Muncie - IN Precision forgings
Cincinnati - OH Electro-chemical milling
of blades and vanes
Manchester - CT Precision machining of
fan blades and outer guide vanes
N. Charlestown - NH Precision machining of
fan blades and outer guide vanes
Engine Products East
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Composites at GKN Aerospace
Comprehensive Capabilities Design, Manufacture, Test and Certify
Full Range of Technologies and Materials Hand Lay-up Automated Tape Laying Fiber Placement Filament Winding RTM And RFI
Advanced Composite Manufacture and Bonding Complex Structure Assembly and Integration Turnkey Manufacturing Facilities Composite Research Centers
GEnx Composite Fan Case
737 Blended Winglet
A400M Composite Wing Spar
RTM – Fan Platform
Largest Composite Aerostructures Supplier in the World (non OEM)
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Composite Structures Manufacturing
Clean Rooms, Hand Layup, ATL, AFP
Pattern Cutting/Machining
Honeycomb Machining
Laser Ply Lay-up and Inspection
Bonded Composite/Metallic Assemblies
Autoclave and Oven Cure
Automated Drill and Trim
Inspection – Automated Ultrasonic Inspection System (AUIS)
Coordinate Measurement Machines
Fully Equipped M&P Laboratory
Fiber Placement Automated Drilling Center
Autoclaves NDI - AUIS
Complete Component Through Complex Assembly Fabrication Expertise
RTM
Auto Tape Layers Filament Winding Tape Winding
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Integrated Assembly
Manufacturing Work Cell Facility Layout
Lean Initiatives Applied to Each Program
Dedicated Customer Assembly Areas
Fully Integrated Products
Part-to-Part Assembly Philosophy
State of the Art Ergonomic Assembly Tooling Supporting Part-to-Part Process
Wing Trailing Edge Fan Cowl Door
Winglet
Engine Nacelle
Horizontal Stabilizer
787 Floor Assembly
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Strategic Outlook – GKN ACS
GKN ALABAMA Workforce of 1000 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 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 Key capabilities
Hand Laminates
Carbon/Kevlar/Glass Fabric
Components delivery to GKN AL
Leader in Composite
Structures for the Aircraft and Engine Markets
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Health and Safety
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Continuous Improvement focused on Think Safe! Campaign
Significant improvements through the years
No Loss Time Accident for the past 3+ million production hours
TRR < 2.0, beating our target
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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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Alabama Leadership Team
VP and General Manager Daniele Cagnatel
Director of Quality Eric Baker
Director of Supply Chain Jay Woodrow
Director of Continuous Improvement
Rebecca Siers
Director of Finance Les Emanuel
GM Composite - Mexicali Loren Engel
Executive Assistant Donna Johnson
Director of Engineering Richie Hodges
Director of Human Resources Michelle Alcathie
Director of Manufacturing Rich Rogoski
Director of Bus. Dev. & IT Frank Greco
Director of Commercial Bus. Chelsea Mclaughlin
GM South Carolina Steve Pulliam
Director of Programs Tony Garnett
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GKN ACS Background
1985 – Tallassee, Alabama site established by Sikorsky Aircraft to manufacture composite details for the Blackhawk helicopter
1990 – United Technologies (Sikorsky and P&W) formed the Dow-UT joint venture with Dow Chemicals
1998 – Dow-UT acquired by GKN Aerospace
1999 – Montgomery site opened for transition of major assemblies from Sikorsky
2000-2002 – Business volume doubled by moving work from the UK (Airbus, MRAS) and adding to customer base (Lockheed Martin, GE)
2003 - 2006 – Continued to grow business through new GE/Boeing, Lockheed Martin, and Airbus programs together with new manufacturing technologies
2007 GKN invested with GE on the Gen-x first all composite case and formed
2008- Awarded Development program on Honda Jet
2009 – Relocated the Montgomery Assembly in the Tallassee expansion
2012 – Opened two new manufacturing facilities Mexicali & Orangeburg, SC
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Alabama Growth
500
Employees
$85
Million
2004
631
Employees
$127 Million
2005
761
Employees
$150 Million
2006
529 Employees
$68
Million
2003
Alabama Sales and Employment Growth
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
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Market Segments and Key Platforms for Growth
Composite Engine Components
GE 90 (B777)
GE CF6 (B767)
GE Genx-1B (B787)
P&W 4000/6000
Nacelle Cowlings
Blocker Doors
Composite Structure Components
Helicopter components and assemblies
Commercial Aircraft
Military Aircraft
Rotorblades
Integrated Assembly structures (equipped, heater elements etc.)
Assembly Structures Honda Fuselage
Honda Wings
Commercial Aircraft Assemblies
GKN ALABAMA / MEXICALI
GKN ALABAMA / MEXICALI
GKN ALABAMA / SC
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Customer Relationships
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Boeing Military Lockheed Martin Bell Helicopter Hondajet
Rolls Royce Boeing Commercial UTC Aerospace Systems
Key Strong Existing Relationships
Strategically Targeted
Airbus GE Aviation Pratt & Whitney Sikorsky
Strategic Objectives Expansion of content with key existing customers Capture content with targeted customers (Boeing, RR, Airbus, Bell) Improve customer balance to reduce market risk & increase growth potential on the Commercial Business (Rolls-Royce / Boeing)
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Market Growth
GKN ACS is well positioned for growth
Composite aircraft structures is forecasted to grow at a CAGR of 11.2% from 2011-2021. High Volume Hand Lay-up supports low costs and completive advantage
Advance technology used for specific application only
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GKN ASC South Carolina
Strategic Objective: Locate low cost assembly site near key customers to off-load OEM scope & accelerate growth
Current Status 150,000 Sq. Ft. – New Facility – Production Ready
22 Acre site
Dedicated site for complex assembly
Facility production startup with Honeywell engine fan duct assembly Oct 2012
HondaJet Fuselage and subassemblies occupy ~25% of current facility
Qualification for CF6 Assemblies started with GE
GKN SC
Launch Team
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Product Sikorsky components successfully transferred
Qualification for GE: project plan in work, request for qualification initiated by end of Sept
GKN ACS Mexicali
Strategic Objectives Low Cost Competitive Enabler to GKN Aerospace North America
Offset Support to OEM’s Pursuit of Mexican Market
Capacity Enabler to Alabama / ANA Growth Strategy
Strategic Objectives
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GKN ACS - Alabama
~$280M 2012 sales
~1000 employees (non-union)
Total of 380,000 square feet of
manufacturing area
Land to expand ~325 acres
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ACS Core Competencies
Design and build small to medium complex composite assemblies
Primary structure hybrid assemblies
Composite fan case and acoustics assembly
Systems installation
Low cost US supplier for core competencies
Sikorsky UH-60 Blackhawk
Lockheed Martin F-22 Raptor
Airbus Jetliners
GEnx Engine
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Clean rooms/ hand lay-up with Laser Ply Projection (95th SF)
Gerber cutting systems (3) for composite materials Two Gerber tables 60 ft long
One Gerber table 45 ft long
Autoclaves (8 each, largest is 15’ X 50’)
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Manufacturing Facilities
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Two CNC Honeycomb machining
GFM single cut tables
CNC machining of parts
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Manufacturing Facilities
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Manufacturing Facilities
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
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Quality Assurance
> Quality certifications/Approvals > ISO9001:2008 > AS9100-Rev. C > NADCAP - Composite & NDT > United Technologies ASQR-01 > Approved Supplier for Airbus, GE, Lockheed Martin > AS9102 - First Article Inspection (FAI) > Sikorsky Supplier Gold – “Awarded as Performing” > ISO14001:2004 > OHSAS 18001:2007
> Non Destructive Inspection > ASNT Level III Manager
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The Lean Enterprise Model
GKN Vision
(PE)
(PrE) (BPE)
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Common Language – With Focus Area’s
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Our Competence and Differentiator: Our People!
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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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