Today’s Agenda
Morning
GKN Aerospace Western Approach
Presentation
Site tour
Lunch enroute
Afternoon
Celtic Manor
Divisional presentations
Financial overview
Wrap up 1730h
Evening
Reconvene at 1830h
Technology showcase and drinks
Dinner
GKN Capital Markets Day – 12 April 2011
1
22 months of Progress in Western Approach
Marcus Bryson
GKN Capital Markets Day – 12 April 2011
Facility Development – Western Approach
GKN Capital Markets Day – 12 April 2011
3
Facility Development – Western Approach
Creating a world class capability
GKN Capital Markets Day – 12 April 2011
4
Facility Development – Western Approach
GKN Lease commencement - April
2009
GKN Capital Markets Day – 12 April 2011
5
Facility Development – Western Approach
GKN Lease commencement - April
Ground Breaking – May 2009
2009
GKN Capital Markets Day – 12 April 2011
6
Facility Development – Western Approach
Ground Breaking
Foundations
– May –
2009
July 2009
GKN Capital Markets Day – 12 April 2011
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Facility Development – Western Approach
Foundations – July 2009
AFP installation starts Nov 2009 &
Handover April 2010
GKN Capital Markets Day – 12 April 2011
8
Facility Development – Western Approach
Autoclave
installation
AFP installation
starts Nov
2009 & Sept 2010 &
Handover
Handover April
2010 Jan 2011
GKN Capital Markets Day – 12 April 2011
9
Facility Development – Western Approach
Clean Room and Facility Finished
22 Months from Empty Shell to Factory Start Up.
Autoclave installation Sept 2010 &
Handover Jan 2011
GKN Capital Markets Day – 12 April 2011
10
GKN
Delivering Sustainable Growth
GKN Aerospace – European Aerostructures
Phil Swash
GKN Capital Markets Day – 12 April 2011
GKNA Filton 2 years on……
Largest acquisition performed by GKNA
1500 personnel and over £300m annual
sales
Integration successfully completed and
now into third year of strong and profitable
contribution to GKN plc
New working practices agreement
concluded in 2010
Customer satisfaction very high
Major new (non-Airbus) design and build
contract secured in Q4 2010
Filton Site
Filton Site
Focus now on driving growth
Western Approach
Advanced Composite
Manufacture and Assembly Site
GKN Capital Markets Day – 12 April 2011
12
A350 XWB
Wider, more comfortable Cabin
incorporating innovative Airbus Cabin
Vision features and personalised IFE
Light, robust,
repairable structure
Aerodynamics for Mach 0.85
cruise with unequalled levels
of efficiency
Advanced Rolls Royce Trent XWB
Engines delivering best levels of
fuel efficiency, maintainability
and environmental impact
A380 Systems and
Cockpit commonality
Three variants:
A350-800 – 270 pax
A350-900 – 314 pax
A350-1000 – 350 pax
571 Orders (28th Feb 2011) from 34
customers
A350-800
156
A350-900
340
A350-1000 75
GKN Capital Markets Day – 12 April 2011
13
GKN A350 Participation, over $2m per ship-set
Fixed Trailing Edge (FTE) assembly, landing flaps,
cabin windows, and RR Trent XWB engine products
(thrust struts, inner core fairings and blisks)
Programme involvement spans:
Engineering design, process development, tooling and
manufacturing
Introducing new technologies, e.g. advanced fibre
placement and automated assembly systems
Creation of our GKNA Centre of Excellence for
composite spars (Western Approach) – A400M spars
now also produced here
Over £170m to be invested by GKNA over 5 years
Fully integrated product teams working closely with
customer and supply chain
First A350 flying parts now in production
GKN Capital Markets Day – 12 April 2011
14
A350 FTE & Assembly Design
Outer Spar - 9.3m
Mid Spar - 10.4m
Inner Spar - 7.5m
Three spars total over 27m in length with an accuracy of +/- 0.2mm
The Fixed Trailing Edge assembly will weigh 1,630kg
Over 500km of carbon tows (6.35mm * 0.25mm) used to make a
set of spars, laid at 10kg/hr at full rate (hand-lay is c.1kg/hr)
The FTE is 7% of total wing weight and supports 10x its own weight
GKN Capital Markets Day – 12 April 2011
15
Composites Manufacture
Five state of the art AFP machines
Two 13m long autoclaves
Three five-axis router / water jet machining centre
NDT C-scan
Up to 15m individual component manufacture
Flexible manufacturing system
Ability to lay UD pre-peg material over complex
geometry
Greater accuracy (more rigidity in gantry systems)
Reduced recurring cutter costs
Produces lighter components than other methods
Clean Room layout
GKN Capital Markets Day – 12 April 2011
16
Spar Process Flow
Goods In
Advanced
Fibre
Placement
Mandrel
Preparation
Autoclave
Cure
Router
Hot
De-Bulk
Non Destructive
Testing
Transfer to
Cure Tool
Paint
To
Assembly
GKN Capital Markets Day – 12 April 2011
17
Composite Assembly
Four five-axis heavy drilling and precision
finishing machines
Robotic technology for light drilling and
precision machining
Moveable jigs
Step forward in FTE methodology
Flexible manufacturing system
High level of quality and repeatability
High payload capability extends flexibility
Automated Guided Vehicles (AGVs) for jig /
component transportation
Multiple AGV linking to carry longer
components
Ease of new product introduction
GKN Capital Markets Day – 12 April 2011
18
Assembly Process Flow
Spar
and
Details
MRS & ORS Robot
Drill
Load to Jig
IRS 5 Axis Drill
Move
Bolt & Assemble
Despatch
Digital Scan Joint
GKN Capital Markets Day – 12 April 2011
Spar
Integration
Robotic drill &
Integrate
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