Integrated aviation manufacturing solutions

AS-GEN-2-022-001 ISS 3

SCOPE OF ACTIVITIES

• The provision of design support for incorporation of modifications.

(N/A for EASA Part 21G POA)

• The manufacture and supply of aircraft parts & assemblies using metallics, composites and electrical products.

(For EASA Part 21G POA – as per approved scope and Capability list)

INTERESTED PARTIESType of interested party: Interested in:

Customers (current) Product delivered on time, on quality and on price

Customers (potential) Same as above plus expansion or change to their supply chain or new requirement

Regulatory Authorities (Aviation) Regulatory compliance and product safety

Regulatory Authorities (Training) Regulatory compliance, training standards and valid formally skilled artisan

Type of interested party: Interested in:

3rd Party certification bodies Compliance with requirements and standards, product safety

External providers (Suppliers, subcontractors, service and training providers)

Continued business from Aerosud

Shareholders Return on investment

Partners Continued business and collaboration with Aerosud

Associations Collaboration to maintain and grow business in the aviation sector

Financial institutions Loan payback InvestmentsIndependent financial auditing (service supplier)

INTERESTED PARTIES (continued)

Type of interested party: Interested in:

Internal workforce Salary income and personal self-realisation

Unions Maintaining member numbers and independent representation of member interests

Government and provincial Compliance with lawsGrants and industry assistanceBBBEEOHS

Municipalities Compliance with By-laws and industry assistanceOHS

Competitors Taking business away from Aerosud

Group Introduction

Organisation

AS/EN 9100

• Chemical Processing & Paint• Heat Treatment • TIG Welding • Composites Part 21G POA

IDC26%

Paramount27%

Employee Trust12%

Management Trust6%

Original Shareholders

29%

Aerosud Holdings

Group Introduction

Privately owned company – Established in 1990

Aerosud Innovation and

Training Centre (IC)

Black Economic Empowered (BBBEE) - Level 5 contributor (latest code) Positioning for significant growthIDC remains the future financier of the Company

B737/B747/B77726%

A32017%

A32011%

A400M20%

A400M13%

A3506%

Other7%

Customer Profile

Annual Turnover: 1.0bRand (70mUSD) Staff : 500

Facilities

Located in Tshwane, South Africa – 20 minutes by highway to OR Tambo International airport

Office Floor space: 3 000 sqmManufacturing Floor space: 13 000 sqmWarehousing Floor space: 2 800 sqmSub-con management 200 sqmReceiving facility 400 sqmDispatch Facility 300 sqm

Aerosud Manufacturing Capability

Machine Processing

Sheet Metal Fabrication

Composite Lay-up Fabrication

Flat Sandwich Panels Processing

Thermoplastic Fabrication

CFRTP Fabrication

Pipe Forming

Electrical Wiring

Sew &Stitch

Welded Assembly

Composite Monuments

Thermoplastic Assembly

Composite Assembly

Major Metal Assembly

CFTRP Assembly

Aerosud Welded Assembly

NC Routing(3-axis)

Sheet Metal Fabrication

1

A350 Track Can

Heat Treatment Forming

Setup

Machine Processing

2

Machining CMM Inspection

NC Bending

Pipe Forming

7

Surface Treatment (CAA, CCC, TSA)

Paint

Surface Treatment (CAA, CCC,

TSA)

Welded Assembly

Robotic Welding

(TiG)

Paint Application

(Primer, Finish Coat)

Minor Assembly

A380 Ramps

A320 Track CanSpot Welding

ManualWelding

(TiG)

Aerosud CFRTP Assembly

NC Routing(3-axis)

Sheet Metal Fabrication

1

Heat Treatment

Forming

Machine Processing

CFRTP Assembly

Mechanical

Sub-Assembly

Bonding

Sub-Assembly

Paint Application

(Primer & Finish)

A400M Stowage Box

A400M Cargo Linings Connection Units

A350 Clips

Material Cutting

Minor Assembly(Bonding)

Sew and Stitch

Material Drying

Material Cutting

Thermo Forming

CFRTP Fabrication

NC Trim(5-axis)

C-Scan Inspection

Sealing

Final Assembly

2

9

6

Setup Machining CMM Inspection

Sew and Stitch

Aerosud Thermoplastic Assembly

Sheet Metal Fabrication

Machine Processing

Thermoplastic Fabrication

Thermoplastic Assembly

1

2

5

NC Routing(3-axis)

Heat Treatment

Forming

Setup Machining CMM Inspection

NC Trip(5-axis)

Vacuum Forming

Bonding

Sub-Assembly

Paint Application

(Primer & Finish)

Final Assembly

A400M Cockpit Window Linings

B777 Cockpit Stowage Box

B737 Drip Trays

Material Cutting

Material Drying

Aerosud Composite Monuments

Sheet Metal Fabrication

Machine Processing

Flat Sandwich Panels Processing

Pipe Forming

Electrical Wiring

Composite Monuments

1

2

4

7

8

NC Routing(3-axis)

Heat Treatment

Forming

Setup Machining CMM Inspection

NC Routing(3-axis)

Minor Assembly(Bonding)

Testing

PaintNC Bending Surface Treatment(CAA, CCC, TSA)

Wire Cutting and Printing (Laser)

Minor Assembly ID Testing

Bonded

Sub-Assembly

SystemsSub-Assembly

(Water & Waste)

Functional

Testing

Paint Application

(Primer & Finish)

ElectricalSub-Assembly

(Electrical Box)

Final

Assembly

A400M Galley

A320 Galley 1

A400M NBC Storage

Aerosud Major Metallic Assembly

NC Routing(3-axis)

Heat Treatment

Forming

Setup

Machine Processing

2

Machining CMM Inspection

Ply Cutting

Composite Lay-up Fabrication

3

Lay-up Oven Cure NC Trim(5-axis)

Material Cutting

5

Material Drying

Vacuum Forming

NC Trim(5-axis)

Wire Cutting and Printing (Laser)

Electrical Wiring

Minor Assembly

ID Testing

Major Metallic Assembly

Mechanical

Sub-Assembly

Final AssemblyPaint Application

(Primer & Finish)

A400M Wingtip

A320 VU

A400M 4th

Occupant Seat

Omega Assembly

Sheet Metal Fabrication

1

8

Thermoplastic Fabrication

Product Development

Facilities and Capabilities

Capabilities AIRBUS AP1020

A core team of experienced engineers and designers in:

• Structural design, analysis and qualification• Systems design, analysis and qualification• Environmental qualification

Well established relationships with internationally recognised design and engineering service providers allows the ability to ramp up

Facilities• DS Catia V5 with DS Smarteam• MSC Nastran/Patran (linear & non-linear)• AIRBUS ASSIST & In-house developed tools (static stress) • Fluent & Saber Modeling• Basic material testing

Outsourced Testing• Structural & Fatigue• Environmental (RTCA DO 160) • Fire-Smoke-Toxicity-Heat Release

Manufacturing Engineering

Facilities and Capabilities

Capabilities

• Manufacturing process implementation, development and qualification

• Interpretation of OEM process specifications into easy to use Build Manuals

• Creation of Process Planning Sheets(job cards/shop travellers)

• 3-axis & 5-axis NC programming• CMM programming• Design & manufacture of metallic & composite tooling

together with well established South African based tooling manufacturers

Facilities

• DS Catia V5 with DS Smarteam• SIGMANEST• MASTERCAM• PC DMIS• POWER INSPECT

Risk Management

Creating Business Content and identify Objectives

Business Systems

Business Systems Overview

SFDC - Shop Floor Data Collection

Operational Processes and Procedures (OPPS)(EN/AS 9100 Compliant)

ERP

SolutionInventory

Production

SFDC

Detail parts tracking

Priority Management

Part Quality Reporting

WIP Management PLM

Solution

PDM

EBOM/MBOM

ConfigurationWorkflow

SYMPHONYPurchasing

Financial Management

Manufacturing Engineering Tool Ω OMEGA

SubconManagement