Phase 1 PresentationAerospace Forging – California Drop Forge
Board of DirectorsNovember 20, 2014
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Introduction
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What is our game plan?
Our focus is on critical aerospace forging applications using sophisticated materials that are highly complex metallurgically, where there is a strong barrier to entry, and where value can be added beyond the forging.
We focus on stainless, titanium and nickel materials where often there is not enough industry capability.
We add value through post forging operations (blasting, machining, heat treatment).
We focus on applications with current and potential customers where there are customer approval barriers or quality requirements (NADCAP, AS9100)
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Auxiliary Power Unit (APU)Forged Titanium impeller for the exhaust section
Forged titanium inlet compressor section
Engine
We provide forgings for the following applications
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Aircraft Structural
Landing gear
Closed die Forging for the engine attach pylon from 15-5ph steel
Closed die forging for landing gear strut from 300 Maraging Steel
We provide forgings for the following applications
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Flight ControlForged high strength 17-4 ph steel for flight control actuators
We provide forgings for the following applications
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0
20
40
60
2006
14.4
11.0
9.5
4.74.5
46
2007
20.7
12.0
10.3
5.24.9
54
2008
18.2
9.5
7.2
5.8
5.9
47
2009
7.9
4.35.64.1
25
2010
9.1
4.14.44.0
24
2011
11.2
5.6
6.63.0
29
2012
12.3
3.96.43.3
29
2013
12.6
5.7
4.83.2
28
2014FC
14.5
4.74.9
28
We have lost share in the aerospace market since the recession in 2009. We have been flat since 2011.
Sales History – California Drop Forge
CAGR 1.6% (2009 – 2014FC)$M
’09-’14CAGR
10.7%
1.9%
-1.9%
APUs
EnginesAirframe Medical
-13.5%Landing Gear
1.6%Total
We have been growing well in APUs, but have been challenged in other areas.
In Medical, we lost to low cost competition and are not focused on growing there due to a wealth of opportunity in aerospace.
-12%
Market growth rate 5% YOY
FCS 0%
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Margins grow markedly over timeCDF Gross Margins by Product Line
Gross margins improve overall by 610 basis points since 2005
12 mos 12 mos 12 mos 12 mos 12 mos 12 mos 12 mos 12 mos 12 mos 9 mos2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
Product LineAPUs 24.3% 23.3% 30.1% 26.8% 30.0% 22.4% 18.4% 16.8% 20.9% 26.5%Engines 18.2% 22.3% 33.0% 34.3% 31.5% 27.0% 22.5% 24.4% 27.7% 31.3%Airframe Structural 20.7% 34.9% 44.3% 49.2% 52.9% 51.8% 44.4% 40.5% 45.3% 47.3%Medical 34.2% 25.3% 27.0% 27.8% 42.4% 51.1% 38.4% 38.9% 38.1% 31.7%Landing Gear 11.3% 29.8% 32.6% 31.7% 30.5% 23.9% 21.1% 29.1% 27.2% 28.9%Flight Control 19.4% 21.6% 49.0% 43.7% 39.4% 35.9% 21.9% 27.7% 29.1% 32.0%Die Fab 17.1% 25.2% N.A. 25.7% 42.0% -7.8% 27.5% 54.4% 46.2% 28.8%Total 25.4% 26.3% 33.6% 32.6% 37.8% 33.4% 27.4% 27.0% 29.0% 31.5%
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0
10
20
2009
7.3
3.5
1.5
15
2010
7.1
3.5
0.9
1.3
15
2011
9.2
2.3
2.3
1.41.3
1.4
20
2012
9.8
1.9
2.8
1.01.1
1.4
20
2013
9.6
1.7
2.6
1.2
19
2014FC
12.7
2.4
1.61.01.10.8
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We have grown in our top customers because of Honeywell (which is labelled as Honeywell, LPI and Aeronamic below)
Sales History – Cal Drop.For Top-10 Customers$M
Honeywell
Lockheed
Total
Due to responsiveness, we have grown Honeywell significantly. Beckman declines because of our share loss to Chinese competition. We have lost many customers such as CT Tool, Berkshire, Capo, Northstar Aero, BTL due to
inflexibility of our T’s & C’s. We lost at Ducommun due to a design change to composites. We will drill into our lost historical customers to determine root cause and corrective action.
Aeronamic
Beckman
.
LPI
ALP
’09-’14CAGR
12%
29%
-6%
9%
7%
66%
NMF
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We have not penetrated new aircraft platforms. This causes a problem for us in the future because the growth in
Aerospace is on these new programs
We have content on the 787 on the APU, but no other content on the 787 or other new aircraft (E2, A350, C-Series, A320-NEO, A330-NEO, 737-MAX, 777-X, JSF)
Some Content No Content
Boeing 787
Embraer E2
Airbus A350
Bombardier C-Series
Airbus A320/330 Neo
Boeing 737-Max
Boeing 777-X
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The diagrams below show forging applications on an aircraft. CDF can provide most of the items below. PMP
can do items in red (up to 80 pounds).
APUFuel Injection NozzleRotor CompressorShroudsShaftImpeller
EnginesHot Zone Combuster Discs Bliscs ShaftCold Zone Compressor Rings Discs Impeller Gear Box Blades/Vanes
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Landing GearNoseDrag BraceMain ShaftSide BraceCylindersStrutTorque ArmsWheel Axle
Airframe/Structural (see next page)PylonRudder Flap TrackStiffenersNacelle
Flight ControlsActuatorsServocylindersThrust Reversers
The diagrams below show forging applications on an aircraft. CDF can provide most of the items below. PMP
can do items in red (up to 80 pounds).
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This is another view of the forging content on an aircraft
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0
20
40
60
80
100%
APU Engines
Precision Cast Parts
Sifco
Alcoa
Allegheny
631
Landing Gear
Precision Cast Parts
Alcoa
Schultz
VSMPO
1,184
Airframe/Structural
Precision Cast Parts
Alcoa
Weber
SchultzVSMPOBoehler1,411
HBD
36
HBD
HBD
Boehler
HBD
Flight Control
HBD
29
Total = 3,291
This is the market for all forged products in Aerospace
Forgings in the Aerospace Market
HBD is a small player focused on APUs. We win because others have difficulty doing complex forgings.
We believe we can extend into engines and airframes without much difficulty (target is Precision Cast Parts)
15
0
20
40
60
80
100%
APU Engines
GE
Rolls Royce
Snecma
631
Landing Gear
Honeywell
Safran
HerouxELEB
1,184
Airframe/Structural
Magellan
OEMs
Spirit
GKN
Triumph
1,410
Honeywell
UTC
36
UTC
UTC
Flight Control
Parker
Moog
30
Total = 3,290.4
This the market for forgings by customer. We have a position in APUs, but little outside APUs despite having
capability to compete.
Customers in the Aerospace Market
We already have approvals at Spirit (because we are Boeing approved), UTC and Honeywell. For many parts we already have tooling. We believe we can grow with these customers.
We need to get on approval lists elsewhere, but believe we can win at GE, Spirit, Safran and Rolls-Royce
We believe there is also an opportunity to supply the hard metal machining suppliers to the Tier 1 suppliers highlighted above.
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We have 3000 dies in our CDF warehouse that could be used to capture existing forgings on existing programs.
Example Dies in Inventory
We need to review our 3000 dies to determine which are still active.
We have 175 dies for Boeing alone (737, 747, 777, F-22, F-15, F-18, C-17, Apache AH-64, CH-47). We may be able to capture content with these dies (particularly 737, 777).
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This the market for forgings by press type Press type in the Aerospace Forging Market
HBD plays in the $380M Drop Hammer market. This process creates high fracture toughness.
PMP has an opportunity in the screw press market for engines (no sales today). We believe that mechanical presses would be a beneficial complement to our drop
hammer competency. Faster cycle time, lower cost.
0
20
40
60
80
100%
APU Engines
Drop Hammer (High Fracture Tough)
Hydraulic Press
Seamless Forge Rings
(Hydraulic Press)
Screw Press
631
Landing Gear
Mechanical Press
Hydraulic Press
1,184
Airframe/Structural
Drop Hammer (High Fracture Tough)
Mechanical Press
Hydraulic Press
1,411
Flight Control
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Total = 3,291
18
0
25
50
75
100%
APU
Drop Hammer Press
Hydraulic Press
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Engines
Drop Hammer Press
Hydraulic Press
6 1
Airframe/Structural
Drop Hammer Press
5 1
Landing Gear
Flight Control
Our sales break down into drop hammer presses and hydraulic presses
California Drop Forge Sales by Press Type2013 = $30M
2/3 of our business is in Drop Hammer presses. We developed hydraulic press capabilities in the past 4-5 years because our customer
asked us to for more dimensionally precise requirements PMP has no commercial aerospace sales today, but has capability that we can exploit
for smaller parts that are utilized on engines and APUs (rotating components)
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The previous slides have shown you that…
• We have grown slower than the Aerospace market in recent years
• We have thwarted our own growth by not having front end resources or by restrictive policies
• We are quoting a lot of business, but not yielding adequate sales
• We are not positioned adequately on new aero programs• We play in a large market where we believe we can win and
grow substantially• We believe we can grow fast with existing customers and their
machining suppliers where we are approved and have dies.• We believe we can be successful at gaining approvals and
share at a short list of Tier 1 and Tier 2 customers where we do not have a position today.
Our Problem Statements and Hypotheses address the items above.
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Problem Statement 1
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Problem Statement 1
In the Aerospace market, we face challenges due to a lack of sales and marketing, as well as prohibitive sales policies. We have not seen consistent growth because we have failed to market the company, and potential customers do not know who we are. Additionally, we have had customer unfriendly policies that have caused us to lose business.
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Hypothesis 1: In Aerospace, there a few major OEMs where we could get significant (10s of millions of dollars) new business. In some OEMs we already have approvals and dies and have a quick path
to growth (Boeing, UTC, Honeywell). In other OEMs we need to get on approval lists, but can gain significant new business relatively easily (GE, Spirit, Safran-Microturbo, Rolls).
Boeing Spirit Bell HelicopterAirbus Rolls Royce GE UTC 0
2
4
6
8
10
12
Opportunities in Millions of Dollars
Current CDF Market Share
$15M target opportunity Opportunity at Aerospace OEMs
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Hypothesis 2: An expedited path to Aerospace major OEMs (where we are already approved) is through hard metal machining suppliers.
GKN DASCO AMG Cadence TECT Triumph Magellan ASCO LMT0
2
4
6
8
10
12
Opportunities in Millions of DollarsCurrent CDF Market Share
$20M target opportunity Opportunity at Hard Metal Machining Suppliers
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Hypothesis 3: We can identify $10M in new business on upcoming new aircraft (777x, 737 Max, A320NEO,Bombardier C Series Embraer E2).
C Series
$10M Target Opportunity
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Hypothesis 5: We can exploit PMP’s capabilities for smaller sized parts that are integrated into larger structures in the Aerospace market (primarily in engine OEMs
once we gain penetration at Pratt, Rolls-Royce, GE).
PMP has the ability and equipment to forge intricate parts that may require the use of specific forging equipment. (hydraulic, screw, mechanical and high velocity presses)
Aerospace quality accreditation (AS 9100)
Compliment CDF capabilities with smaller size forgings. (less than 80 LB)
Blades, vanes and nozzles are components within PMP’s capabilities.
$30M to $40M Opportunity