GKN Aerospace Visit
Filton and Western Approach
Guy Stainer | 10th February 2015
GKN Aerospace Proprietary and Confidential
GKN: A Tier 1 Supplier to the major OE manufacturers in
Automotive, Aerospace and Land Systems markets
Global engineering group
Sales of £7.6 billion in 2013 (£5.6bn 9 mths to
end Sept 2014, with 8.9% trading margin)
GKN Aerospace
A leading first tier supplier to the
global aerospace industry.
48,000 people in more than 30 countries
2013 - Sales by division
Land Systems
(12%)
£899m
Other
(1%)
£104m
Driveline
(45%)
£3,416m
Aerospace
(30%)
£2,243m
GKN Driveline
A world leading supplier of
automotive driveline systems
and solutions.
GKN Powder Metallurgy
One of the world’s largest
manufacturers of metal powder
and sintered components.
GKN Land Systems
A leading supplier of engineered
power management products,
systems and services.
Powder Metallurgy
(12%)
£932m
All group financial data in this document relates to 2013 unless otherwise stated. Sales figures are presented on a management basis
GKN Aerospace Proprietary and Confidential
Clear strategy: five key elements
Four strong divisions
Creating long-term
shareholder value
Five strategic
objectives
Lead in chosen
markets
Growth target:
Above market
Growth
Leverage global
footprint
Technology driving
margin
Margin
Operational
excellence
BUSINESS
PERFORMANCE
Target: 20%
Group target:
8-10%
Cash Flow
Sustain above
market growth
GKN Aerospace Proprietary and Confidential
ROIC
Increasing cash flow,
EPS and dividends
GKN Aerospace
£2.2billion International Aerospace enterprise
32 sites, approx 12,000 people
Daniele Cagnatel
GKN Aerospace
Aerostructures
North America
John Pritchard
GKN Aerospace
Aerostructures
Europe
Gavin Wesson
GKN Aerospace
Special Products
Group
Mike McCann
GKN Aerospace
Engine Systems
GKN Aerospace Proprietary and Confidential
Kevin Cummings
CEO
GKN Aerospace
GKN Aerospace
GKN Aerospace Proprietary and Confidential
GKN Aerospace – World class product portfolio
Aerostructures
Engine structures
Special
products
45% of Sales 2013
50% of Sales 2013
5% of Sales 2013
Wing
Fuselage
Nacelle and
Pylon
Engine Systems and Services
Engine structures
Engine rotatives
Transparencies
and Protection
Systems
J-UCAS Fuselage
A380 Fixed Trailing Edge
B747-8 Exhaust
B787 Anti-icing System
A350XWB Rear Spar
CH53K Aft Fuselage
A400M Engine Intake
V22 Fuel Tanks
A330 Flap Skins
B787 Floor Grid
B767 Winglet
HondaJet Fuselage
B787 Cabin Windows
B787 Inner Core Cowl
Full Engine MRO and support
Ariane 5 Exhaust nozzle
GKN Aerospace Proprietary and Confidential
F35 Canopy
Market drivers bringing opportunities
Drivers
Requirement
Solution
Engine
technology
changes –
Fuel price
Noise
legislation
Increasing
passenger
travel in
emerging
markets
Higher fuel
efficiency
hotter cores,
lighter fans
Better noise
attenuation
New materials
–composite
fans/cases,
titanium
replacing
composites
Increasing
demand for
aircraft
Airlines
renewing
fleets
sooner
GKN Aerospace Proprietary and Confidential
GKN opportunity
GKN technology
composite fans and
cases for future large
aircraft
Strong position on
geared turbo-fan
Specialist titanium
engine structures for
next generation engines
Winglets and future
wings
Light weight composite
Increased new aircraft
sales
GKN Aerospace – well positioned for the future
GKN Aerospace Proprietary and Confidential
Technology – Targeted innovation
Future product differentiation
Future wing
technologies
Advanced
fuselage
Nacelle, pylon
and exhaust
Engine
structures
Engine
rotatives
Next generation
composite processes
Advanced
metallic processes
Advanced process development
GKN Aerospace Proprietary and Confidential
Transparencies
and coatings
Ice protection
systems
Welcome to
GKN Aerospace Filton
John Pritchard, CEO Aerostructures Europe
GKN Aerospace Proprietary and Confidential
Filton – A Century of aircraft manufacturing expertise
1910
British & Colonial Aeroplane Company founded at Filton – Bristol Boxkite first
aircraft manufactured
2,000 aircraft built at Filton.: Bristol fighter, Bulldog, Blenheim, Scout,
Bristol Aeroplane Company formed
1939
Factory doubles in size to become largest aircraft factory in the world
Beaufighter first flight.
Concrete runways installed
1945
Over 52,000 employees on payroll
Brabazon Airliner first flight
1960
Britannia first flight
Concorde
British Aerospace – BAe 146 fuselage production, Tornado components
1980
A310 Trailing Edge
A320 Wings
A321 Fuselage section
2008
A330 / 340: major sub-assemblies
F1-11 refurbishment
GKN Aerospace Proprietary and Confidential
A380 Fixed Trailing Edge
GKN Aerospace Filton – What We Do Today
Sales: £387m
2009
Workforce: >1,800
Programmes:
Large Civil: Airbus A320 family, A330, A380,
Boeing 787
Military Transport: A400M
Business Jet: Dassault Falcon 5X
Military Fast Jet: Joint Strike Fighter
Filton Engineering Centre established
Over 200 design and engineering specialists
Today
Additive Manufacturing Centre
Horizon Project
EcoHVP
GKN Aerospace Proprietary and Confidential
Key Capabilities
Major Assembly and Integration:
Wing Box
Leading Edge
Trailing Edge
Flight control surfaces
Machined Structural Components
Ribs
Gear ribs
Pintle Fitting
Advanced Systems
Fuel
Hydraulic
Pneumatic
Anti-Ice and Bleed Air
GKN Aerospace Proprietary and Confidential
GKN Filton – A Growing Business Investing in the Future
New Customers
Joint Strike Fighter
Dassault
Boeing
Triumph
Facilities
> £30M capital investment since 2009
£30M projected over next 3 yrs (~70% on increasing capacity)
Filton Engineering Centre established
New technology investment – Linear Friction
Welding & Additive Manufacture
People
Safety
Employee engagement
Education and Community support
Apprenticeship programmes – supporting the site
infrastructure & ensuring we are fit for the future
GKN Aerospace Proprietary and Confidential
GKN Additive Manufacturing
What is Additive Manufacturing?
Traditional machining removes material to create parts
Machined from solid - high waste levels
Design constrained by machine capability
Additive Manufacture creates parts layer by layer – 3D printing
Only uses the material you need - less waste
Design no longer constrained by conventional manufacturing processes
Allows design for functionality
A revolutionary set of technologies – not evolutionary
Phased introduction is implicitly required
Secondary derivative structure before primary optimised
Need to pin variables to gain acceptance
Process and material are now linked like never before
Big challenge to the industry in evaluation
How to certify
New and novel QA techniques required
GKN Aerospace Proprietary and Confidential
Site Tour
Integrated Machining Facility
A380 Fixed Trailing Edge
Additive Manufacturing Centre
GKN Aerospace Proprietary and Confidential
Welcome to GKN Aerospace
Western Approach
Steve Colebrook
10th February 2015
Safety – GKN Core Value
• Please stay with your host at all times
• Remain within designated gangways whilst on production floor
• PPE rules to be respected at all times
• Keep hands-off raw material and cured carbon
• No Test Fire Alarm schedule for today
• Emergency Exits are clearly identified, remain with your host and follow
them to the Muster point
Have a Safe and Enjoyable visit
2
GKN Western Approach
•
£170M invested in new state-of-the-art composite wing structures
manufacturing and assembly facility
•
Over 30,000m2 of floor space
3
Advancing GKN Capabilities on A350XWB
Western Approach – GKN’s Centre of Excellence for major
composite primary structure components
First Advanced Fibre Placement spar manufacture – largest
composite part in GKN
First FTE automated moving assembly system
Fully integrated product teams working closely with
customer and supply chain
4
A350 Fixed Trailing Edge Design
Outer Spar
Mid Spar
Inner Spar
3 Spars total over 27m in length with an accuracy of +/- 0.3mm
Total weight of spar carbon is 1230kg/aircraft
FTE assembly weighs 1800kg
The FTE is 7% of total wing weight and supports 10x its own weight
First “large scale” assembly operation undertaken by GKN
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Spar Process Flow
Goods In
Mandrel
Preparation
Autoclave
Cure
Router
Transfer to
Cure Tool
Advanced Fibre
Placement
Non Destructive
Testing
Paint
Rib-Post Assy
To
Assembly
6
Assembly Process Flow
Spar
and
Details
MRS & ORS Robot
Drill
Load to Jig
IRS 5 Axis Drill
Move
Bolt & Assemble
Despatch
Spar
Integration
Digital Scan Joint
7
Robotic drill &
Integrate
Integration Jig – Port & Stbd
8
FTE in Jig Customer
9
Wing Static Test
10
A400M Atlas
11
ATL Manufacture
12
A400M Spar Manufacture
13
A400m Stiffeners – Composite Details
14
Tour of Western Approach
Visits to:
Advanced Composites Centre of Excellence
Automated Assembly Facility
Thank you for your visit
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