february 2011 page 2 -...
TRANSCRIPT
Page 2
February 2011
Page 3
Index
AERNNOVA ENGINEERING DESCRIPTION
Introduction
Activities
Capabilities and Services Scope
Geographical Presence
Organization
Resources
References
IT Infrastructure and Testing Facilities
Engineering Certifications
Page 4
Since its beginning, Aernnova has considered of maximum importance to have strong and flexible Product and Manufacturing
Engineering, specially in Composites where the Fabrication and Design experience combined is a Real Competitive Advantage.
Aernnova has accumulated a large experience and the recognition of Customers in the Design and Industrialization of Complete
Aerostructures, both in Composites or Metallic.
Since 2006, the Group has organized its Engineering Activities in a Business Division specialized in providing Engineering Services,
usually with Full Responsibility Workpackages, to Aernnova or to External Customers (e.g. Boeing, Bombardier, Hawker Beechcraft,
Airbus, Goodrich, etc.).
Most of the Aernnova Engineering activities are related to Design and Manufacturing of Aerostructures. The acquisition of Serra by
Aernnova in 2008, and its subsequent integration in Aernnova Engineering, has added to this division additional Aeronautical and
Automotive Manufacturing Engineering Activities.
Introduction
Page 5
• Integral Capabilities, from Weight,
and Lofting Specifications to develop:
Conceptual Design, Trade Offs, Detail
Design, Testing, Certification and
Sustaining Engineering.
• Centers in Vitoria, Madrid, USA and
Brazil.
• Complete Work packages or
Technical Assistance.
• Design Organization Approval (DOA)
by EASA.
• > 7 million hours experience.
• Design and Automation of:
Aerostructures Assembly Lines
Composites Manufacturing
Systems.
Tooling and Advanced
Manufacturing Processes.
• Manufacturing Engineering Support.
• > 1 million hours experience.
Aeronautical Engineering Automotive Engineering
Aernnova Engineering
Product Engineering Manufacturing Engineering
• Design and Turn Key Delivery of
Automotive Assembly and Welding
Lines.
• Design, Analysis and Simulation of
Automated Solutions.
• Welding Guns, Electronic Controls
and Machines.
• Transformers.
• Bolt and Nut Feeders.
• Technical Assistance
Automated Assembly Lines Welding Systems
902 Employees
626 Employees 276 Employees
Activities
+64 Contractors mainly in Product Engineering = 966 Total Resources
Page 6
− Integrated Customer
Services (ICS)
− Repair DOA, POA, MOA
− Aircraft on Ground
Support, AOG 365d/ 24h
− Maintenance Support
− Technical Publications
− Material Review Board
− Production Non
Conformities Disposition
− Aerostructures Assembly
Lines
− Composite
Manufacturing Systems
− Tooling and Advanced
Manufacturing Processes
(Design, Set Up and
Fabrication Support)
− Lean Manufacturing
− Training and Transfers
− Liaison with Airworthiness
Authorities
− Materials & Processes
− Certification Tests Analysis
− Systems and Vendor Items
Qualification
− Internal & External Audits
− Certification DOA, MOA,
POA
− Certification Compliance Plan
Definition & Follow Up
− Integral Test Management
− EMI/EMC/ Lightning
− Test Results
− Material Qualification
− Leakage & Pressure tests
− Flight Test Instrumentation
− Flight Test Support
− Endurance
− Fire, Smoke
− Ground Test, etc.
− Performances
− Aeroelasticity
− Flight Physics
− Loads Analysis
− Preliminary and
Conceptual Design
Aernnova Engineering provides Integral Capabilities from Preliminary and Conceptual Definition to Product Support, and a Flexible Scope of
Services along the Project Life Cycle Complete Workpackages, Technical Assistance and Programs Management Support.
Aernnova is an approved organization for design (DOA), production (POA) and maintenance (MOA) as certified by Airworthiness Authorities.
Testing CertificationManufacturing &
AssemblingProduct Support
Design and Development
Prelim. & Conc. Definition
Projects Management (Multisite IT Infrastructure)
Engineering Capabilities and Services Scope
− Structures Design (Metallic
& Composite)
− Systems Design
− Weight Control Manag.
− Damage Tolerance
− FEM Modelling
− Thermal Analysis
− Mechanisms Definition
− Structural Repair Manuals
− Test Plans
− Materials Engineering, etc.
- Concurrent Engineering
Page 7
In parallell to the Main Activities (Product and Manufacturing Engineering) , Aernnova Engineering integrates other Technical Assistance
Activities, organized as well as Specialized Business Units, with the aim to:
Increase Flexibility, Quick Reaction Capacity and Competitiveness.
Support the Growth
Additional Business
Technical Assistance Services
ARGHOS TECHNICAL ASSISTANCE
‒ Engineers or Groups Support
‒ Product, Systems and Manufacturing
Engineering
‒ Customers:
• Aernnova
• External: 24 (40 % Revenues)
‒ Sectors:
• Aeronautics
• Energy
• Trains
• Defense
STAFFING IT SERVICESPERSONNEL AND TRAINING
MANAGEMENT
STRELIA
‒ IT Infrastructure and Multisite Systems
‒ PLM / ERP Integration
‒ Managed Services, Provider
‒ Customers:
• Aernnova
• External: In progress
‒ Sectors:
• Aeronautics
ARGHOS CONSULTING
‒ Personnel Management:
• Recruitment
• Organization
• Expatriates
‒ Training Management
‒ Customers:
• Aernnova
• Objective to Expand
‒ Sectors
• Aeronautics
Page 8
The Engineering Division is developing a Global Footprint:
― Aeronautical Product Engineering: Spain (Vitoria and Madrid), USA, Brazil (India in the 1st Half 2011).
― Aeronautical Manufacturing Engineering: Spain (Vitoria and Barcelona) and Romania.
― Automotive Engineering: Spain (Barcelona) and Brazil.
Geographical Presence
Page 9
Organization
Aernnova Engineering
Pedro Fuente
Product EngineeringAES
J. Ignacio Ibarreche
Vitoria Fernando Campo
MadridM.A. Castillo
USAJ. Carlos Ortiz
BrazilAdel Ben - Smida
Support Services
IT ServicesStrelia
J. Angel Bravo
Training and Personnel Management Arghos Consulting
Elena Yeregui
Manufacturing EngineeringAME/Serra
Javier Tapuerca
AeronauticalManufacturing
Engineering
Technical AssistanceArghos Technical Assistance
Marc Salomon
AutomatedAssembly Lines
WeldingSystems
Aernnova ManufacturingEngineering
AMEAbelardo Serrano
Serra AeronauticsAlejandro Peña
RomaniaSantiago Otegui
Serra AutomotiveTheo Slangen
PyssaAnselmo Sells
Serra SoldaduraJavier Tapuerca
ElesaPablo infante
Serra Do BrasilRafael Ronconi
Page 10
AES (Aernnova Engineering Solutions)
Product Engineering Organization
MANAGING DIRECTORJ.I. Ibarreche
HUMAN RESOURCES DIRECTOR
J. Menor
FINANCE & ECONOMIC DIRECTOR
F. MolásSYSTEMS COMERCIAL
DIRECTOR
A. Esquisabel
CERTIFICATION , TEST & QUALITY DIRECTOR
P. Verdugo
DESIGN & WEIGTHS DIRECTOR
P. Alvarez
STRESS ENGINEERING DIRECTOR
F. Rebollo
PROJECTS MANAGEMENT & CONFIGURATION DIRECTOR
J.I. Uriarte
ENGINEERING SUPPORT &
MATERIALS DIRECTOR
I. Moreno
AES VITORIAMANAGING DIRECTOR
F. Campo
AE BRASILMANAGING DIRECTOR
Adel Ben-Smida
AES IBERICAMANAGING DIRECTOR
M.A. Castillo
AE US MANAGING DIRECTOR
J.C. OrtizCHIEF OF MATERIALS &
PROCESSES J.Valer
MRB METALIC NORTH
B. Arrausi
MRB METALIC CENTRE
J.A. Romero
MRB COMPOSITE NORTH
E. S. De Argandoña
ENGINEERING MANAGERBOEING CLIENT
J.Rodriguez
ENGINEERING MANAGER BOMBARDIER CLIENT
P.Pomar
TESTING MANAGEMENTS.Anaya
DATA & DOCUMENTATIONSERVICES
LABORATORY
MRB COMPOSITE CENTRE
I. Velasco
COMERCIAL DIRECTOR
A. Martinez
TECHNOLOGICAL DEVELOPMENT MANAGER
I. Otero
TECHNICAL DIRECTOR
E. Belotto
Page 11
AME / SERRA (Aernnova Manufacturing Engineering)
Manufacturing Engineering Organization
Manufacturing EngineeringAME/Serra
Javier Tapuerca
AeronauticalManufacturing
Engineering
AutomatedAssembly Lines
WeldingSystems
Aernnova ManufacturingEngineering
AMEAbelardo Serrano
Serra AeronauticsAlejandro Peña
RomaniaSantiago Otegui
Serra AutomotiveTheo Slangen
PyssaAnselmo Sells
Serra SoldaduraJoaquin Suazo
ElesaPablo infante
Serra Do BrasilRafael Ronconi
Page 12
PhD+ MSc 492
BSc 150
Prof .Educ. 260
Aernnova Engineering
Aeronautical Engineering Automotive Engineering
Product EngineeringManufacturing Engineering
Automated Assembly Lines
WeldingSystems
626 Employees
532 94 120 156
276 Employees
Distribution of Total Resources 966 by Type of Contract
Distribution of Employees by Level of Education
Distribution of Employees by Professional Levels
Tech. Mgr., Engineers or Technicians
652
Staf f92
Manual Workers
158
902 Employees
Resources
Permanent 794
Eventual 108
External 64
Data january 2010
Page 13
Aeronautical Engineers and Technicians
Employees Breakdown by Disciplines
Resources
Design 224 Factory Support Engineering 25
Stres 179 Tooling Designers 33
Engineering Quality Certification &
Testing10
Manufacturing Processes
Engineering32
Conf. Control & Project Management 17 IT and Other Technicians 32
Materials and Special Process
Engineering10 Management & Other Overheads 64
Discipline # Discipline #
TOTAL = 626 Aeronautical Engineers and Technicians
Data january 2010
Page 14
Aeronautical Engineers and Technicians
Design and Analysis Employees Breakdown
DesignEngineer V
> 15 yr
Engineer IV
> 10 yr
Engineer III
> 7 yr
Engineer II
> 4 yr
Engineer I
> 2 yr
Technical
DesignersTOTAL
Composite Structures
Design5 8 15 5 2 36 71
Metallic Structures
Design8 15 30 11 2 70 136
Mechanisms Design --- 2 5 3 4 3 17
TOTAL 13 25 50 19 8 109 224
AnalysisStress Engineer V
> 15 yr
Stress Engineer IV
> 10 yr
Stress Engineer III
> 7 yr
Stress Engineer II
> 4 yr
Stress Engineer I
> 2 yrTOTAL
FEM (Loads) 3 5 8 8 --- 24
Stress Metallic 6 8 31 35 3 83
Stress Composites 6 7 12 13 3 41
Stress Mechanisms --- 1 8 8 --- 17
Fatigue and DT 1 3 5 5 --- 14
TOTAL 16 24 64 69 6 179
Resources
Data january 2010
Page 15
IT Tools
Testing Facilities
W/S & Catia Pc´s 531
PDM I-MAN
CAD CATIA, PRO ENG.
FEM PATRAN NASTRAN Promech., Dytran
CRAK. PROP. Fracture Research, Nasgro
Other Transcendent Fibersim, Matlab, Own Software
Materials ANN Lab EUITA INASMET
Structures CTA
Fire CTA
Other CTA - HALT / INTA / CEAT
IT Tools and Testing Facilities
ISAMI
Data january 2010
Page 16
Software
Design (Structures and Systems)
― CATIA V4 & V5.
― Fibersim.
Structural Analysis:
Static & Dynamic (MSC-Nastran/ISAMI)
Pre- Post Processing- Patran, Hypermesh.
Non Linear Analysis- ABAQUS, MSC- MARC.
Impact Analysis (MSC-DYTRAN, ABAQUS).
Weight Reduction Optistruct.
PDM (Product Data Management) iMan V5&V7(UC)
Materials and Processes
Development of Standards and Specs.
Materials and Processes Qualifications
Simulation
DELMIA
Robcad
CAM Software
Unigraphics
CATIA
Software and Multisite System
Page 17
Wings
Embraer
• Complete Wing:
• Wing Box
• Leading Edge
• Trailing Edge
• Wing Tip/Winglet
• Control Surfaces: flaps, ailerons, spoilers.
• Systems: Electrical, Fuel, Hydraulics, Flight Control,
Anti-ice and EMI/EMC
Customer Aircraft Work Packages Scope
Boeing • B747-8• Wing Box: Spars, Skins and Stringers.
• Control Surfaces: Spoilers and Ailerons.
• Detail Design
• Certification Support
Product Engineering Main References
Hawker
Beechcradt
• Premier Hawker
Family• Wing Box, Leading Edge, Trailing Edge, Wing
Tip/Winglet, Control Surfaces and High Lift Devices.
• Conceptual and
Preliminary Design
• Concept Trade offs
• Optimal Solution
• ERJ-145 Family
• Conceptual Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
Page 18
Embraer• EMB- 170/190
• Complete Horizontal Stabilizer:
‒ Main Box Structure
‒ Elevators
‒ Systems Provisions
‒ Ground and Flight Test Instrumentation
• Conceptual Design
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
Bombardier• CRJ700/900/
1000 Family
• Complete Horizontal Stabilizers
‒ Main Box Structure
‒ Elevators
‒ Systems Provisions
• Detail Design (only
900/1000 version)
• Engineering Support
• Liaison Engineering
Airbus• Airbus 350
XWB
• Complete Horizontal Stabilizers
‒ Main Box Structure
‒ Elevators
‒ Electric and Hydraulic Systems Design
‒ Ground & Flight Test Instrumentation
• Conceptual Design
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
Horizontal Stabilizers
Customer Aircraft Work Packages Scope
Product Engineering Main References
Page 19
Embraer• EMB-170/190
Family
• Complete Vertical Stabilizers
‒ Main box structure
‒ Rudder
‒ Systems provisions
‒ Ground and flight test instrumentation
• Conceptual Design
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
Bombardier• CRJ 700/900/
1000 Family
• Complete Vertical Stabilizers
‒ Main Box Structure
‒ Systems Provisions
• Detail Design (only 900/1000
version)
• Engineering Support
• Liaison Engineering
Vertical Stabilizers
Customer Aircraft Work Packages Scope
Product Engineering Main References
Page 20
Embraer• EMB-170/190
Family
• Complete Rear Fuselages
‒ Main structure
‒ Systems provisions
‒ Ground and flight test instrumentation
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
Bombardier • C Series
• Tail Cone
‒ Main structure
‒ Systems provisions
‒ Ground and flight test instrumentation
• Preliminary Design
Airbus • A 380
• S19 Internal Structure
‒ Systems Provisions
‒ Ground and Flight Test Instrumentation
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
Boeing • B 747 LCF
• Rear Fuselage (Swing Zone)
‒ Fuselage Structure
‒ Mechanisms for Folding
‒ Provisions for Latches
• Conceptual Design
• Detail Design
• Manufacturing Support
Rear Fuselages
Customer Aircraft Work Packages Scope
Product Engineering Main References
Page 21
Boeing • B 747-8
• Section 42 FWD & AFT
‒ Main Structure
‒ Systems Provisions
• Detail Design
• Certification Support
Bombardier
• C Series
• Center Wing Box:
‒ Full Composite Structure
‒ Systems Provisions
‒ Ground and Flight Test instrumentation
• Conceptual Design
• Preliminary Design
• Detail Design
• Prototypes
• Material Qualification
• Design Allowable
Embraer • ERJ-145 Family •Belly Fairing
• Conceptual Design
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
Central Fuselage and Fairings
Customer Aircraft Work Packages Scope
• Bullet Fairings • Aerodynamic Shaped Composites Panels
• Detail Design
• Certification
• Liaison Engineering
Product Engineering Main References
Page 22
Sikorsky • S-92
• Horizontal Stabilizer
‒ Composite Main Box
‒ Flight Test Instrument
• Conceptual Design
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
• Aft Transition Tail Cone
• Fuselage Structure
• Composite Ramp
• Mechanics
• Main rotor pylon:
‒ Composite Structure
‒ System Interfaces
‒ Cabin Interfaces
‒ Engines Cowling
‒ Engine Exhaust
•Civil and Utility Interiors:
‒ Composite Supporting Structure, Ceiling Panels,
Electrical System Installation, Air Condition Ducts,
Fire Extinguishing Systems
Helicopters
Customer Aircraft Work Packages Scope
• Systems Installation
• Ground & Flight Tests
Instrum.
• Folded & Mechanism
Product Engineering Main References
Page 23
Flightech
Systems
• ALTEA
(MTOW 75 Kg.)
• Aerodynamic Shape and Loads Definition
• Performance Analysis
• Complete CFRP Structure Design:
‒ Fuselage
‒ Wing
‒ Empennage
‒ Front and Main Landing Gear
• Servo-actuators Definition
• Engine, Fuel Tank and Parachute Integration
• Prototypes Manufacturing
• Aerodynamic Design
• Conceptual Design
• Preliminary Design
• Detail Design
• Testing
• Certification Support
• Manuf. Engineering
• Liaison Engineering
Avibras• FALCAO
(MTOW 600 Kg.)
• Complete CFRP Structure Design:
‒ Fuselage
‒ Wing
‒ Empennage
‒ Front and Main Landing Gear
‒ Engine, Fuel Tank and Parachute Integration
• Conceptual Design
• Preliminary Design
• Detail Design
• Manuf. Engineering
• Liaison Engineering
UAV´s
Customer Aircraft Work Packages Scope
Product Engineering Main References
Page 24
Others
Embraer • RJ-145 Family
• Thrust Reverser
‒ Fixed Structure
‒ Systems Assembly
‒ Blocking Doors
Airbus • A350 XWB
•Pressure Bulkhead MLGB
‒ Complete Composite Structure
‒ Provisions for Systems
Eurofighter • EF-2000•Flare Dispenser
‒ Composite Solution
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
• Concept Design
• Preliminary Design
• Detail Design
• Testing
• Certification
• Prototypes
• Liaison Engineering
• Conceptual Design
• Detail design
• Testing
• Certification
• Prototypes
• Liaison engineering
Customer Aircraft Work Packages Scope
Product Engineering Main References