KTM Solutions, Inc.
Company Overview – General
Prepared for
SBIOI - Charleston, SC
April 22, 2010
Rob McDaris – Senior Engineer/Charleston Business Development
Company Overview
KTM Solutions, Inc enables aerospace,
automotive, and machine design
companies to successfully complete
urgent mechanical and structural design
projects without overwhelming or
enlarging existing staff.
Our seasoned engineering staff
averages 20 years of engineering
experience!
On Demand
On Demand Engineering® Engineering and management resources
available when you need them
• Mechanical Design / Structural Analysis
•
•
•
•
•
•
•
Aircraft / Automotive / Product Development
2D Drawing / 3D Modeling
Classical Static Strength
Durability and Damage Tolerance (DADT)
Finite Element Modeling
Reverse engineering
FAA Certification Process
• Project Management / Systems Engineering
On Demand Engineering® means service starts when we receive your call
Our Team
• Experienced Workforce /
Ample Capacity
–
–
–
–
24 full time/part time
5 registered engineers
Average experience 20 years
Experience ranges from conveyor
design to aircraft high lift systems
KTM Solutions Depth Chart
Design
Engineer
Number
8*
19
20
21
1*
2*
3
4
5
6
7
22
10
14
15
17
16*
Highest
Degree
BSME
ASMET
BSME
BSME
BSME
MSAE
BSME
MSME
BSME**
MSAE
ASMET
ASMET
PHDEM
Years
Exp
41
18
1
1
25
10
6
21
7
25
33
19
7
2
2
4
28
Class
MD
TD
EA
EA
MD
MD
SA
SA
MD
SA
MD
MD
EA
EA
EA
TD
SA
CATIA
X
X
X
X
X
X
X
X
X
X
X
X
X
Stress
SWORK
Other
X
X
X
X
X
X
(1) .
(1).
(1).
(1).
ANSYS
(1)(2)(5)
X
X
(4)(5)
X
Classical
NAST
X
X
X
X
X
X
D&DT
Other
X
(3)(9)
X
(6)(7)
(1)(2)
X
X
X
X
X
X
X
(1) .
(1).
(1).
(1).
Capacity - On Demand
X
(10).
Industry Experience
Mach
Aircraft
Auto
DSN
L
H
H
H
L
L
H
L
L
H
L
L
H
L
H
H
H
H
H
H
L
M
H
L
L
L
L
L
L
L
L
M
Corporate Governance:
– April 2005, KTM Solutions, Inc. – A South Carolina
Corporation (Woman Owned Small Business)
– Ginger A. Kumler – CEO, Business Manager
– Paul V. Kumler P.E. – President, Chief Engineer
Certifications/Credentials:
– Registered Engineering Company, South Carolina
– Licensed Professional Engineering, South Carolina
– Senior Engineering Management Experience with
Fortune 50 Aircraft Companies
Facilities:
– 4000 ft2 Greenville, SC (Headquarters)
– 2000 ft2 North Charleston, SC (Planned 3 QTR 2010)
Aerospace
Aerospace Experienced Engineering Staff –
Senior KTM engineers and management were trained and developed by large
aersopace companies (Boeing, Lockheed Martin, Raytheon and USAF)
Structural/Mechanical and Analysis –
Primary structures (wing, body, empennage) design and analysis; electrical
rack/packaging; and secondary structural design; aircraft modification
Key Clients –
Aircraft OEM’s
Aircraft Tier I Suppliers
Aircraft Modification Facilities
Aircraft structural design and analysis is historically 60% of our business
Aircraft Primary Structures
Key Capabilities
– Primary and secondary structural design
and analysis
•
•
•
•
•
•
3D Modeling (CATIAv5/SolidWorks)
Manufacturing Drawings
Static strength
Durability and Damage Tolerance
FAA Certification Planning
Finite Element Analysis (NASTRAN/FEMAP)
– Mechanical systems / high lift devices
• Control surfaces and systems
• Landing gear
• Hydraulic components
– Modification and repair of legacy aircraft
• Shipside support
• Materials Review Board (MRB)
• Aircraft upgrades
– Systems Engineering and Project
Management
Recently completed wing upgrade – Business Jet OEM (Kansas)
Tool Engineering
• Major Assembly Fixtures
–
–
–
–
–
–
–
Locating Jigs
Holding Fixtures
Large platforms
Assembly fixtures
Welding fixtures
Retrofit jigs
Pneumatic and electrical systems
• Hand Tool Development and
Improvement
– Modified hand tools
– Small assembly fixtures, holding
fixtures
– Specialty tools
Reverse Engineering
• Material Properties Analysis
– Forensic material analysis including
alloy identification and heat
treat/hardening
– Failure investigations
– Part usage and environment
considerations
– Improvement recommendations
• Geometric Analysis and
Assembly Study
– Dimensional analysis of manufactured
parts
– Part to part relationship and tolerance
study
– Manufacturing drawings developed from
3D design
New Development
• Mechanical and Structural
Systems Design
– Packaging of mechanical
components
– Structural integrity through
defined operating spectrum
– Component selection
– Design refinement using
existing products
• Customer Certification and
Compliance
– Support of European Union
(CE) certification
– Matching existing interfaces
Conveyor Related Systems
• New conveyor systems
– Materials and component selection
based on industry standards
– Maximize use of “off the shelf
hardware and equipment (lowers
cost)
– Custom design for each unique
application (physical parameters,
temperature, operational
characteristics)
• Reverse engineering for
component obsolescence
– Match existing equipment and
interfaces
– Meet or extend life cycle goals
Machine Design
• Material Processing Machinery
– Systems designed to process raw
materials into product
– Off the shelf components matched to
designed hardware
– Complete systems architecture
– Simplified operator interfaces and
safety devices
– Designed to meet life cycle and
operational goals
• Maintenance and Repair
– Reverse engineering of individual
components to extend machine life
– Simulation and analysis of
operational problems
Heavy Lifting Systems
• Design and Analysis of Box
Girder Beams
– Double beam girders
– Lower mount single girders
– Torsional girder beams
10 ton working load
• Common analysis
packages
– FEM/FEA
– Hand structural analysis using
conventional methods
– Optimization of design for
lowest weight (material costs)
Systems Engineering
Inputs:
• Program Controls and
Plans
Requirements accountability
Requirements Verification
Risk Management
Design progress reviews
Integrated Master Schedules
Contract/SOW/Spec integration
• Integrated Product Teams
– All stakeholders
– Concurrent design process
• RFP
• SOW
SRR
• Conduct Systems Studies
• Identify desired capabilities
and functional requirements
• Develop Operational
Scenarios
• Conduct System Trades
• Prepare Systems
Specification
• Prepare Proposal
Outputs:
SEQ #
447500
SDR
PDR
CDR
Inputs:
•
•
•
•
•
•
Basic
Design
SOW
Detail
CDRL
Design
Proposal
Top Level Spec
Results of Concept Definition
Preliminary Plans
Unit Cooling
455500
Power
System
Test
Verf.
Procedure
Verification
results
•
Use Tasks:
Mechanical
Formally tested
• Integrated systems
Analysis tests
hardware and
software
Tools to• Systems fixes
elements prove. • Update Design
• Integrated and
Documentation to
reflect as built/as
TBDchecked outRun
system
qualified
Diagnostics
configuration
to Verify.
• Prepare final test
• SDR Package
2
CONT 2.1
CONT 2.6
06151B31
Outputs:
• FCA/PCA Data Packages
• Final Documentation
• Specs
• Engineering
• O&M Manuals
• Test Plans, Procedures,
reports
• Contract Compliance
Documents
documentation
Number
Warning
be installed
on each for
CONT
2.1 placards
06151A10 shall
Provide
structural attachments
supporting
10 pound LRU
on forward
assembly that is powered
by multiple
power
bulkhead at sta 360, WL 200, BL 30R
sources.
within +/- 2 inches
06151A11
Production
Inputs:
TBD
Reliability and performance requirements shall be Demo
TBD
Run
Requirement
AccountabilityDiagnostics
Matrix
met with an inlet water temperature of +70 deg
F.
SOW
Requirement
Owner
Method of
Due
Date
Cross
to Verify.
Authority
• Released
Engineering
• Final Part II ICD’s
• Initail product
Fabrication
Specifications
• CDR Data Package
I&CO
Part 1 ICD’sshall be
All Ship Safety/Self Protect •equipment
Test
• Subcontractor Packages
capable of operation over
the ambient
air
• Trade
Study Reports
temperature range of +40
deg to
+104 deg F.
• Final
Plans
Reqmt
Number
1
3
• Complete Detail Design
• Generate Part II ICD’s
• Develop initial
production Fabrication
specifications
• Technical Performance
Measurement
• Generate detail test
requirements and test
procedures
Element
Test
• Initial
448000
Outputs:
Fab
subjected to the combined conditions of pitch,
roll, and yaw listed inOutputs:
Table 3.4.1.1-1.
Air Temperature
Tasks:
• Part 1 Specification
and Interface Baseline
• Basic Design
Approach
RQMT’s
Allocation
• Operational Concept
• Systems Specification
Tasks:
• Systems Trade Study
Reports
• Systems Trades
Preliminary Requirement
Development
Section •Title
Verf.
• Requirements Allocation
Plans
Meth.
• Make/Buy
• Proposal
• Initiate Development of
•
Systems
Requirements
Ship's Motion
The equipment design as installed
the ship
Anal
• Part 1on
ICDs
Review Agenda/Data
• Subcontract SPEC, SOW, SDRL
Package shall meet all performance requirements when
447600
FCA/PCA
Inputs:
Concept
Definition
Tasks:
• Initial
• Part 1 ICD’s
• Subcontractor Packages
• Trade Study Reports
• Final Plans
• SDR Package
• Refine Requirements Allocations
• Finalize
• Part 1 ICD’s and Specs
• Subcontractor Packages
• Conduct Design Trades/Analysis
• Develop detail design approach
• Technical performance measurement
Verification
Insp
Jones
Provide structural pentrations through
forward bulkhead at sta 360, WL 200,
BL 30R within +/- 2 inches to
accommodate 6 inch dia wire bundle.
Culpepper
5
Develop systems installation that will
Koslowski
accomdoate RCA 13789A24 Radio
without degradtion of performance in
4
existing radio range. If performance is
degraded, client must decide whether to
3
complete installation
Likelihood
–
–
–
–
–
–
Inputs:
Outputs:
Tasks:
• Initial
• Part 1 ICD’s
• Subcontractor
Packages
• Plans
• Schedules
2
1
TBD
Visual
Visual
Almost
Certain
Test
1-May-09
Reference
Spec 24.3
1-Apr-07
Spec 24.3
Status
Risk Level
Closure Evidence
Open
Low
Drawing Release
Open
Consequence
Med
Drawing Release
Insignificant
Minor
Moderate
Major
1
2
3
4
5
Etest and
Functional
supporting analysis
E
E
1-Apr-07M
Spec 54.3
HOpen
MedH
Catastrophic
Likely
M
M
H
H
Possible
L
M
M
H
E
Unlikely
L
M
M
H
H
Rare
L
L
M
M
H
E – Extreme risk – detailed action plan required
H - High risk – needs senior management attention
M – Medium risk – specify management responsibility
L – Low risk – manage by routine procedures
High or Extreme risks must be reported to Senior Management and require detailed treatment plans to reduce the risk to Low or Medium.
Systems Engineering – KTM PRO 45 (based on MIL-STD-499B)
KTM Quality Management System –
Our processes are designed to provide consistency of product. Processes
(PRO) are authorized by Policy (POL) and audited regularly. Instructions
(INSTR) are released for client unique requirements
They include topics such as:
– Document Control
– Quality Assurance
– Analysis Methods
– Safety Analysis
– Bidding
– Technical Services
– Contracts
– Consulting Services Design
– Technical Reviews
ISO 9001:2008 and AS9100 compliant
Overall Summary
• Mechanical Engineering /
Structural Analysis
–
–
–
–
–
–
–
–
Prototype and Production Design
Static Analysis
Finite Element Modeling
Durability and Damage Tolerance
(DADT)
3D Simulations
Digital Pre-Assembly
Aircraft Certification Compliance
Systems Engineering (MIL-STD
Compliant)
FEA / 3D Models / Simulations / Drawings
Aerospace | Automotive | Machine Design | Product Development
KTM Solutions is a Woman Owned Small Business
Contact Information
•
Postal Service
Ginger A. Kumler – CEO
1095 Thousand Oaks Blvd, Suite 201
Greenville, SC 29607
Paul V. Kumler, P.E. – President
1095 Thousand Oaks Blvd, Suite 201
Greenville, SC 29607
Rob McDaris – Business Development
1095 Thousand Oaks Blvd, Suite 201
Greenville, SC 29607
•
E-Mail
info@ktmsolutions.com
•
Telephone
864-297-6600
•
Facsimile
864-297-5757
FEA / 3D Models / Simulations / Drawings
Thank You!