GKN Aerospace Proprietary and Confidential
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
GKN Aerospace
A leading first tier supplier to the
global aerospace industry.
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.
2013 - Sales by division
Driveline
(45%)
£3,416m
Aerospace
(30%)
£2,243m
Land Systems
(12%)
£899m
Other
(1%)
£104m
All group financial data in this document relates to 2013 unless otherwise stated. Sales figures are presented on a management basis
Powder Metallurgy
(12%)
£932m
Global engineering group
Sales of £7.6 billion in 2013 (£5.6bn 9 mths to
end Sept 2014, with 8.9% trading margin)
48,000 people in more than 30 countries
GKN Aerospace Proprietary and Confidential
Clear strategy: five key elements
Creating long-term
shareholder value Four strong divisions
Lead in chosen markets
Leverage global footprint
Technology driving margin
Operational excellence
Increasing cash flow,
EPS and dividends
BUSINESS
PERFORMANCE
Growth target:
Above market
Group target:
8-10%
Target: 20%
Sustain above
market growth
Cash Flow
Growth
ROIC Margin
Five strategic
objectives
GKN Aerospace Proprietary and Confidential
GKN Aerospace
£2.2billion International Aerospace enterprise
32 sites, approx 12,000 people
Kevin Cummings
CEO
GKN Aerospace
Daniele Cagnatel
GKN Aerospace
Aerostructures
North America
John Pritchard
GKN Aerospace
Aerostructures
Europe
Mike McCann
GKN Aerospace
Engine Systems
Gavin Wesson
GKN Aerospace
Special Products
Group
GKN Aerospace Proprietary and Confidential
GKN Aerospace
GKN Aerospace Proprietary and Confidential
Transparencies
and Protection
Systems
Special products 5% of Sales 2013
Nacelle and
Pylon
Engine structures 50% of Sales 2013
Engine Systems and Services Wing Fuselage
Aerostructures 45% of Sales 2013
A380 Fixed Trailing Edge
A350XWB Rear Spar
A330 Flap Skins
B767 Winglet
J-UCAS Fuselage
CH53K Aft Fuselage
B787 Floor Grid
HondaJet Fuselage F35 Canopy
B787 Cabin Windows
V22 Fuel Tanks
B787 Anti-icing System
Full Engine MRO and support
Ariane 5 Exhaust nozzle
B787 Inner Core Cowl
A400M Engine Intake
B747-8 Exhaust
Engine structures Engine rotatives
GKN Aerospace – World class product portfolio
GKN Aerospace Proprietary and Confidential
Market drivers bringing opportunities
Fuel price
Noise
legislation
Increasing
passenger
travel in
emerging
markets
Higher fuel
efficiency
Better noise
attenuation
Increasing
demand for
aircraft
Engine
technology
changes –
hotter cores,
lighter fans
New materials
–composite
fans/cases,
titanium
replacing
composites
Airlines
renewing
fleets
sooner
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
Drivers GKN opportunity Requirement Solution
GKN Aerospace Proprietary and Confidential
GKN Aerospace – well positioned for the future
GKN Aerospace Proprietary and Confidential
Next generation
composite processes
Advanced
metallic processes
Advanced process development
Transparencies
and coatings
Future product differentiation
Future wing
technologies
Advanced
fuselage
Nacelle, pylon
and exhaust
Engine
structures
Engine
rotatives
Ice protection
systems
Technology – Targeted innovation
GKN Aerospace Proprietary and Confidential
Welcome to
GKN Aerospace Filton
John Pritchard, CEO Aerostructures Europe
GKN Aerospace Proprietary and Confidential
Filton – A Century of aircraft manufacturing expertise
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
Factory doubles in size to become largest aircraft factory in the world
2008
1980
1960
1945
1910
1939
Beaufighter first flight.
Concrete runways installed
Over 52,000 employees on payroll
Brabazon Airliner first flight
Britannia first flight
Concorde
British Aerospace – BAe 146 fuselage production, Tornado components
A310 Trailing Edge
A320 Wings
A321 Fuselage section
A330 / 340: major sub-assemblies
F1-11 refurbishment
A380 Fixed Trailing Edge
GKN Aerospace Proprietary and Confidential
GKN Aerospace Filton – What We Do Today
Sales: £387m
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
Additive Manufacturing Centre
Horizon Project
EcoHVP
2009
Today
GKN Aerospace Proprietary and Confidential
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
Key Capabilities
GKN Aerospace Proprietary and Confidential
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 Filton – A Growing Business Investing in the Future
GKN Aerospace Proprietary and Confidential
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 Additive Manufacturing
GKN Aerospace Proprietary and Confidential
Site Tour
Integrated Machining Facility
A380 Fixed Trailing Edge
Additive Manufacturing Centre
Welcome to GKN Aerospace Western Approach
Steve Colebrook
10th February 2015
2
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
3
GKN Western Approach
• £170M invested in new state-of-the-art composite wing structures
manufacturing and assembly facility
• Over 30,000m2 of floor space
4
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
5
Outer Spar
Mid Spar
Inner Spar
A350 Fixed Trailing Edge Design
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
6
Spar Process Flow
Goods In
Advanced Fibre
Placement
Transfer to
Cure Tool
Autoclave
Cure Router
To
Assembly
Mandrel
Preparation
Paint
Non Destructive
Testing Rib-Post Assy
7
Assembly Process Flow
Spar
and
Details
Despatch
Load to Jig
Spar
Integration
IRS 5 Axis Drill
MRS & ORS Robot
Drill
Bolt & Assemble
Digital Scan Joint Robotic drill &
Integrate
Move
8
Integration Jig – Port & Stbd
9
FTE in Jig Customer
10
Wing Static Test
11
A400M Atlas
12
ATL Manufacture
13
A400M Spar Manufacture
14
A400m Stiffeners – Composite Details
15
Tour of Western Approach
Visits to:
Advanced Composites Centre of Excellence
Automated Assembly Facility
Thank you for your visit