Integrated aviation manufacturing solutions
Transcript of Integrated aviation manufacturing solutions
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
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