Welcome to GKN-ACS
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Business Portfolio & Focus in US
Engine Products
West
Advanced Machine
Structures
Engine Products
East
Advanced Composite
Structures
Aerospace
Structures
Chem-tronics - CA
PreMac - KS
Cincinnati - OH
Alabama
St. Louis - MO
 Leader in fan cases &
rings, engine structures
 Titanium machining &
aluminum wing skin
technology leader
 Electro-chemical milling
of blades and vanes
 Integrated composite
structures & assemblies
 Hard Metal Machining
Orangeburg - SC
 Composite Structures
 Chem-milling & aviation
repair
 Aircraft Subassembly
ASTECH - CA
Monitor - NY
 Welded honeycomb
structures and
fabrications
 Titanium machining
technology leader
 FAA-145 repair station
 High Speed Aluminum
Machining
Manchester - CT
 Precision machining of
fan blades and outer
guide vanes
San Luis Potosi
 Precision forgings
 Low cost fan blade
machining & grinding
N. Charlestown - NH
 Precision machining of
fan blades and outer
guide vanes
Bandy - CA
 Hinge center
 Small Machined Ti and
AL parts
ANA
Headquarters
TX
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 HLU/AFP
 Aircraft Subassembly
Structures - CT
 RTM
 Composites Development
Muncie - IN
 Low cost machining and
fabrication
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Mexicali Composites
 Low cost composite center
Mexicali
 Subassembly
 Aircraft subassembly
 High Speed AL Machining
Composites at GKN Aerospace
Comprehensive Capabilities
Design, Manufacture, Test and Certify
Full Range of Technologies and Materials
Hand Lay-up
GEnx
Composite Fan Case
Automated Tape Laying
Fiber Placement
Filament Winding
RTM And RFI
737 Blended Winglet
Advanced Composite Manufacture and
Bonding
Complex Structure Assembly and
Integration
Turnkey Manufacturing Facilities
RTM – Fan Platform
Composite Research Centers
Largest Composite Aerostructures Supplier in the World (non
OEM)
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A400M Composite Wing Spar
Composite Structures Manufacturing
Clean Rooms, Hand Layup, ATL, AFP
Pattern Cutting/Machining
Honeycomb Machining
Fiber Placement
Laser Ply Lay-up and Inspection
Automated Drilling Center
Bonded Composite/Metallic
Assemblies
Autoclave and Oven Cure
Autoclaves
Automated Drill and Trim
NDI - AUIS
RTM
Inspection – Automated Ultrasonic
Inspection System (AUIS)
Coordinate Measurement Machines
Fully Equipped M&P Laboratory
Auto Tape Layers
Filament Winding
Complete Component Through Complex Assembly Fabrication Expertise
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Tape Winding
Integrated Assembly
Manufacturing Work Cell Facility
Layout
Lean Initiatives Applied to Each
Program
Horizontal Stabilizer
Engine Nacelle
Dedicated Customer Assembly
Areas
Fully Integrated Products
Part-to-Part Assembly Philosophy
State of the Art Ergonomic
Assembly Tooling Supporting
Part-to-Part Process
Fan Cowl Door
Wing Trailing Edge
787 Floor Assembly
Winglet
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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
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
Workforce growth to 300 employees
Key capabilities
Manual Assembly, minimum overhead
Large structures, equipment integration
Business Jet Fuselages, Wings
OEM Floors, Nacelles, Cockpits
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Health and Safety
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:
Eye and Footwear PPE
100% of Factory
Gloves and Hearing PPE
As applicable in designated areas
Stop, Look, Listen
100% of Factory
X
Use Pedestrian Doors
100% of Factory
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Alabama Leadership Team
VP and General Manager
Daniele Cagnatel
Director of Manufacturing
Rich Rogoski
Executive Assistant
Donna Johnson
Director of Bus. Dev. & IT
Frank Greco
Director of Quality
Eric Baker
Director of Engineering
Richie Hodges
Director of Supply Chain
Jay Woodrow
GM South Carolina
Steve Pulliam
Director of Finance
Les Emanuel
GM Composite - Mexicali
Loren Engel
Director of Programs
Tony Garnett
Director of Commercial Bus.
Chelsea Mclaughlin
Director of Continuous
Improvement
Rebecca Siers
Director of Human Resources
Michelle Alcathie
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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
960
980
980
970
877
761
Employees
Employees
$230
Employees
$170
Employees
$68
500
$150
$127
$85
Million
Million
2003
2004
Million
$214
$228
Million
Million
2008
2009
Million
Million
Million
2005
2006
2007
2010
2011
Alabama Sales and Employment Growth
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Million
Million
631
Employees
$276
$250
Employees
529
Employees
Employees
Employees
840
Employees
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2012
Market Segments and Key Platforms for Growth
GKN ALABAMA / MEXICALI
Composite Engine
Components
GE 90 (B777)
GE CF6 (B767)
GE Genx-1B (B787)
P&W 4000/6000
Nacelle Cowlings
Blocker Doors
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GKN ALABAMA / MEXICALI
Composite Structure
Components
GKN ALABAMA / SC
Assembly Structures
Honda Fuselage
Helicopter components
and assemblies
Honda Wings
Commercial Aircraft
Commercial Aircraft
Assemblies
Military Aircraft
Rotorblades
Integrated Assembly
structures (equipped,
heater elements etc.)
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Customer Relationships
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)
Key Strong Existing Relationships
Boeing Military
Airbus
Lockheed Martin
GE Aviation
Bell Helicopter
Pratt & Whitney
Hondajet
Sikorsky
Strategically Targeted
Rolls Royce
Boeing Commercial
UTC Aerospace Systems
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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 20112021.
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
Launch Team
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
GKN SC
HondaJet Fuselage and subassemblies occupy ~25% of
current facility
Qualification for CF6 Assemblies started with GE
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GKN ACS Mexicali
Strategic Objectives
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
Product
Sikorsky components successfully
transferred
Qualification for GE: project plan in work,
request for qualification initiated by end of
Sept
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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
Sikorsky
UH-60 Blackhawk
Primary structure hybrid
assemblies
Lockheed Martin
F-22 Raptor
Composite fan case and
acoustics assembly
Systems installation
Airbus
Jetliners
Low cost US supplier for
core competencies
GEnx Engine
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Manufacturing Facilities
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
Two CNC Honeycomb machining
GFM single cut tables
CNC machining of parts
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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
(BPE)
(PrE)
(PE)
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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
Lead in chosen markets
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
Leverage global
footprint
Technology driving
margin
South Carolina facility for Large Assemblies
Mexicali facility for low cost hand lay-up
Out of Autoclave technologies
Flexible manufacturing systems
Operational excellence
Lean Manufacturing system implemented
as the operational model
Sustain above market
growth
Increase Revenue stream by focussing on high
volume and future growth platforms
(787/NEO/737M)
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