Magazin "take off" - Issue 23

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F A C C
C U S T O M E R
M A G A Z I N E
Technology for Innovative
Engine Composites
New Project
Airbus A330/A340
On the Road to Success
Passenger Cabins for
Legacy 450 and Legacy 500
Serial Production of Flap
Track Fairings Started
FACC Interiors with Strong
Growth in Turnover
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EDITORIAL
Dear readers,
At the beginning of this year, the changes in the
ownership structure of FACC were issues for investors, partners and the media. Now an important
milestone has been reached, and a new, promising
partner has been found. The ACC Kooperationen
und Beteiligungen GmbH has bought 48.125% of
the company shares, thus creating a very good foundation for healthy growth for FACC. The investor and
the board agree on the goals: to strengthen the
excellent position of the company as a development
and system supplier for the aviation industry; well
directed expansion; and a further increase in corporate value. This is the news at the end of a bidding
process that lasted months and that marks an
important milestone in the development of FACC. Dr.
Hannes Androsch, co-partner of the ACC Kooperationen und Beteiligungen GmbH and Chairman of
the Supervisory Board of FACC AG, has written an
article about his confidence in the perspectives of
FACC and the company strategy.
The Interiors division of FACC is weathering the
current adverse financial crisis well - it is developing
extremely well. Various new projects, new customers
and a consistent expansion of the market position
allow the turnover of the division to continue to grow,
and will also do so in the future. In an interview with
take off, Gerhard Mörtenhuber, Vice President Interiors, speaks about the reasons for this success.
Another milestone was reached by the employees of Facility 3 in Ort, Austria. They began serial production of the flap track fairings for the Airbus A330
and A340 after a development phase of only 12
months and carried out the first delivery on schedule. We congratulate them on this milestone and in
this issue report about the details of the project.
Further highlights of the last months were the
expansion of the collaboration with Boeing on the
new Boeing 747-8 program and the delivery of the
1000th outer bypass duct for the BR710 RollsRoyce engine. Read more about this and other
topics on the following pages.
The editorial team hopes you enjoy our new
issue.
Andrea Schachinger
Editor
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CONTENTS
03 No Relief in Sight
04 Ownership in FACC
A Company Geared to the Future
06 New Project:
Passenger Cabins for Legacy 450
and Legacy 500
07 FACC Interiors Division
On the Road to Success
09 Bombardier Learjet:
FACC Delivers the 200th Learjet
Passenger Cabin
10 Airbus A330/A340:
FACC Started Serial Production
of Flap Track Fairings
12 New Boeing 747-8:
FACC Delivers Wing Components
14 Milestone:
1000th Outer Bypass Duct
for a BR710
15 Everyone Waltz!
The Viennese Opera Ball
Published by: FACC AG, Fischerstraße 9, A-4910 Ried/Austria. Editorial Staff: Walter Stephan,
Bernhard Matzner, Andrea Schachinger. Photos: Peter M. Mayr AIC Vienna, Alois Furtner Ried,
Embraer São José dos Campos, Boeing Seattle, ACAC Shanghai, Bombardier Aerospace Montréal,
Andreas Friess/picturedesk.com, Vienna Paint Wien, Oskar Pointecker Mehrnbach, shutterstock.com,
FACC Ried. Design and Composition: Oskar Pointecker, 4941 Mehrnbach.
PS.: We welcome your comments.
takeoff@facc.at
Cover: FACC employee Johannes Probsteder during the installation of
a BR725 Duct on a CNC measuring machine. The examination of all
demanded measures of the duct is performed fully automatic.
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NO RELIEF IN SIGHT
>> The current plight of the economy, especially in the world of finance, leads us to expect turbulent
times. These will accompany and
influence FACC AG in its new era –
in our last issue we reported about
the new company structure. The
United States, Europe and Japan
are now in a recession and the crisis
is holding important financial institutions in its grip, causing a noticeable shortage of available capital.
Effects on the aviation industry have
so far not made themselves felt. If
one considers the information of our
customers, their sector still seems
to be unaffected by the crisis. The
order books of the airplane manufacturers have once again grown
this year. At the end of October the
incoming orders at Airbus and Boeing were over 1,400 planes and surpassed by far the planned 900 airplane deliveries in 2008.
However, all other signs indicate
stormy times in the aviation industry
as well. As a supplier we want to be
prepared in good time and in the
right way. At present the facts are as
follows:
– Air traffic: Compared to last year,
in September the number of passengers worldwide fell by just
under 3%, within America by
8.2% and in Asia by 6.8%.
– Fuel: The fuel prices are under $50
USD per barrel and reduce the
necessity for fuel-efficient airplanes. Individual airlines have
already announced that they will
postpone the delivery of new pla-
nes and continue to use older,
less efficient planes.
– Profit situation of the airlines: Falling fuel prices are basically good
news for suffering airlines. At the
same time, the question must be
asked in how far the global drop in
air traffic could undo this bonus.
– Available assets: Market experts
assume that due to the credit
crunch, already in 2009 around
one third of new airplanes, i.e. $20
billion USD worth of planes to be
delivered, will have to be financed
by airplane manufacturers, since
many financial institutions shun
the financing of airplanes.
– The strengthening US dollar: The
exchange rate of the dollar is basically good news for FACC AG.
However, due to currency hedging
already transacted, this will not
yet be effective and will weigh
itself on business results of the
coming years. In the mid-term
range a strong US dollar will bring
noticeable relief.
Given all these factors, one can
assume that 2009 will be a great
year for airplane deliveries. For the
following years, however, we are
anticipating a reduction of the production rates for the established airplane families. We consider it a
compensation that the A380, Boeing 787 and the ARJ21 programs,
the last of which successfully carried out its first flight on November
28th, which have been greatly effected by delays, are really getting into
full gear. As a result, our production
volume will continue to increase.
The implementation of targeted
measures, together with our strong
backlog and the new reliable
ownership structure, make us confident that our joint efforts will enable
us to master the numerous challenges that the difficult market environment brings.
Walter A. Stephan
Chairman of the Board and CEO
<<
FACC AG
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OWNERSHIP IN FACC –
A Company Geared to the Future
The business year of 2008/09 set a decisive change of
direction for FACC and will present a turnaround in
revenue. The year before we were forced to cope with a
loss on our balance sheets that took the company to the
limits of financing.
>> This negative development had
several causes. Time and again we
were confronted with technical
delays in production and delivery of
new airplane models such as the
Airbus A380 or the Boeing Dreamliner 787.
As a supplier for these models,
FACC had to get involved in their
development from the very beginning and this meant a great financial
strain. The returns on this investment have therefore been delayed.
However, due to the long product
life of airplanes and the reliability of
the models, a high return flow can
be counted on over a long period of
time.
In addition, we had recently been
confronted with a dollar that had
become weaker and weaker. It hit
rock bottom on July 15, 2008, with a
rate of $1.599 to the euro. This
situation put us in a troubling position, since our revenues are on a dollar basis, while around 50% of our
costs are in euros.
“The returns on investment in the A380 and Boeing 787
models have been delayed. However, due to the long product
life of airplanes and the reliability of the models, a high
return flow can be counted on over a long period of time.”
Dr. Hannes Androsch
Chairman of the Supervisory Board of FACC AG
Lastly, there were – and still are –
many internal problems to solve.
The over-riding goal is maximum
cost efficiency and the best possible
quality assurance. Thus the amount
of reworking, for example, must be
reduced to a minimum as quickly as
possible.
At FACC there has also been a
change in the ownership structure.
The shares of the Fischer Group
were taken over in June 2008 by the
ACC Kooperationen und Beteiligungen GmbH. They now have a
48.125 % share of FACC, just like
Austrian Salinen AG. The remaining
shares are owned by Stephan
GmbH. The present owners want to
expand FACC AG into a company
strong enough for the future.
The new owners expressed their
commitment by increasing the company’s capital stock. This step
strengthened our key customers’
confidence in the company, which in
turn freed us from the pressure of
having to look for a strategic investment partner.
Under the present conditions the
company strategy is based on solid
ground. All measures taken should
make it possible for us to break even
at the end of the current business
year and to once again achieve
positive results in the future.
The strategy of FACC is aimed at
further expanding our position as a
reliable and competent partner of
the world’s leading airplane manufacturers. This is to be achieved primarily through innovations as well
as high quality standards at competitive prices and the expansion of
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our product and service spectrum.
FACC should be positioned even
stronger than ever as a supplier of
total solutions.
At present our company is already
one of the fastest growing technology and quality leaders on the global
market for passenger planes. FACC
has reacted to the above-average
longtherm growth of the aviation
sector with a consistent growth strategy. In this context we benefit from
the fact that lightweight construction
keeps gaining in importance in the
aviation industry. Manufacturers of
airplanes and engines are increa-
Austrian
Salinen AG
48.125%
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singly prepared to contract significant parts of their supply chain to
first tier suppliers.
The reconstruction of the organizational structure into profit centers
will also strengthen our competitiveness and profitability, as well as
assure the quality of our components and our reputation for reliability. This in turn will contribute to an
uninterrupted capacity utilization of
our facilities.
FACC AG will continue to be an
attractive employer as we offer our
employees interesting and above all
ACC Kooperationen
u. Beteiligungen GmbH
48.125%
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secure jobs. Even when times are
getting tougher due to the financial
crisis and its real economic effects,
we have no reason to dread the
future.
I would like to thank our customers
for their confidence in us, our
employees for their dedication and
our works council for their constructive cooperation.
Dr. Hannes Androsch
Chairman of the Supervisory Board
<<
of FACC AG
Stephan GmbH
3.75%
In June 2008 the ACC
Kooperationen und
Beteiligungen GmbH
took over the shares of
the Fischer Group. The
present owners want to
FACC AG
strengthen FACC AG
for the future and have
shown their commitment
Ownership structure chart of FACC AG
by increasing the company’s capital stock.
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NEW PROJECT:
Passenger Cabins for Legacy 450
and Legacy 500
Two years ago Embraer chose FACC as a supplier for the first time. The successful
collaboration of the two companies is now being expanded. FACC is developing and
producing the passenger cabins for the Brazilian aircraft manufacturer’s new Legacy
450 and 500 business jets.
>> During the 2008 Farnborough
Airshow, Embraer awarded FACC
with the contract for the development and production of the passenger cabins for their two new Legacy
450 and 500 business jets. The contract includes the manufacturing of
the linings of the main cabin, the
cockpit and the cargo compartment, all furnishings ranging from
the galley to the lavatories, bulkheads, as well as the pocket table.
In August FACC began the detail
development of the passenger
cabins for the Embraer business
jets. At present, in the so-called
“joint definition phase”, FACC is
working together with the customer
and other program suppliers on the
configuration of the planes on site
at the Embraer headquarters in Sao
Jose dos Campos. This is being
carried out in an entirely digital process using a virtual mock-up, CATIA
V5 software and the most modern
analysis, simulation and visualization technologies. In close collaboration with Embraer and the individual
program partners, FACC technicians are developing and defining the
interface to the aircraft, the installation process and the draft design of
the various cabin elements. According to the contract, FACC will deliver the first complete cabin for the
Legacy 500 model to Embraer at
the end of 2010. The interior for the
Legacy 450 will follow a year later.
“Our business relations with our
customer Embraer are still very new,
but are developing extremely positively,” said Gerhard Mörtenhuber,
Vice President Interiors of FACC
AG. “The foundation of this relationship is the optimal and most efficient co-operation of the Embraer
and FACC engineering teams in the
development of new products and
programs. We want to use our comprehensive technological expertise
to contribute to the success of the
two new Embraer business jets.”
The current contract is already
the fourth contract that Embraer
has awarded FACC within the last
two years. In addition to the two
Legacy models, FACC also equips
the Phenom 100, Phenom 300 and
Lineage 1000 business jets with
lightweight interior components.
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“The new Legacy contract and the
other projects with Embraer will significantly help the Interiors Division which could more than double its
turnover in the last fiscal year – to
continue to grow with respect to
turnover and employees,” Mörtenhuber had to say about the pleasing
developments for this division of the
company.
Legacy 450 and Legacy 500
The two Legacy 450 and Legacy 500
business jets have been completely
newly developed by Embraer and
complete the executive jet sector
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portfolio of the airplane manufacturers, whereby the mid-size Legacy
450 will have a range of up to 4,260
km and the super mid-size Legacy
500 a range of up to 5,560 km. The
interior, designed by the BMW Group
Designworks (USA) in co-operation
with Embraer for the two planes,
poses a quantum leap in the development of business jet interiors and
will offer the passengers unsurpassed comfort and style. It is unique
with its roomy cabin stand-up cabin
(1.82 m tall) and a stepless floor, flat
throughout, that makes the cabin
<<
comfortable to walk through.
FACC Interiors Division
ON THE ROAD TO SUCCESS
Considerable growth in turnover, numerous new projects, expansion of the market
position and new customers: the Interior Division of FACC is growing extremely
successfully. take off spoke with Gerhard Mörtenhuber, Vice President of FACC
Interiors, about the reasons behind this success.
take off: Please give our readers
a short overview of the Interior Division.
Mörtenhuber: The interior division
develops, qualifies and produces
complete passenger cabins for the
largest airplane manufacturers like
Airbus, Boeing, Bombardier and
Embraer. Depending on the customer’s wishes, we are in the position
to be involved in a project already at
the beginning of the development
phase by carrying out the industrial
design or merely take over the production of components. In the last
years a clear market trend has
become apparent that is moving
steadily in the direction of vertical
cabin development and cabin integration. We follow this trend and
increasingly act as a complete solution provider covering the entire
value added chain - from cabin
design and development, qualification and certification to manufacturing, installation and customer support
take off: Since its divestment eight
years ago as a separate operation,
how has the Interiors Division developed? What were the highlights?
Mörtenhuber: Eight years ago we
were in a crossroad situation,
namely “grow or give way”. After
intensive discussions with the
owners, customers and our
management we opted for the forward strategy, which at the time
was not self-evident. In hindsight,
we see that the interior team really
stood behind this step and were
totally committed. I am completely
convinced that this was the actual
success factor and why it was acknowledged by the market and
rewarded with contracts.
take off: How does FACC cope
with the rapid ramp-up of aircraft
production, especially of the A320
family for which FACC produces large cabin components? Which measures have been taken to increase
production of interior components
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take off: What are the main reasons
for the successful growth of the division?
Mörtenhuber: There are always
several factors that lead to successful growth. The actual challenge
was not the strategic focus and the
planning itself, but their implementation. A branch that demands more
and more flexibility, that is increasing the pace and at the same time
has distinct conflicts of goals more
than ever calls for an organization
that is shaped by team competency
and the ability to form a consensus.
In spite of diverse issues, we have
fulfilled many of our tasks, but are
still working on some improvements.
"We increasingly act as
a complete solution
in the course of the hike in Airbus
production?
take off: What are your strengths as
compared to the competition and
on the market in general?
provider covering the
entire value added
chain – from cabin
design and development, qualification and
certification to manufacturing, installation
and customer support."
Gerhard Mörtenhuber,
Vice President
FACC Interiors
Mörtenhuber: The development
phase of the A320 cabin went hand
in hand with the development and
start of production of three other
airplane cabins; with the introduction of new projects for Embraer; and
particularly with the escalated production ramp-up of the cabin for the
Bombardier Challenger 300 business jet. The combined implementation of all these programs was the
real challenge. Problems that arose
were recognized on time, communicated openly and successfully solved. In the course of the development and the ramp-up of the new
A320 Enhanced Cabin, a series of
improvements in logistics and production processes were put into
place. Furthermore, each production process was carefully tested to
see which would be the most efficient. Step by step these improvements are being put into place in
every program. All of these new projects can only be managed if the
cooperation between the customer,
the FACC team and suppliers
works. It is also important that our
owners are supportive during difficult phases.
Mörtenhuber: I would like to answer this question with feedback
from our customers. Our customers
see our strengths above all in our
technological innovations, our flexibility as well as in the high level of
quality of our components.
take off: Airplane manufacturers
are reducing their supplier base at
the same time that they are transferring more and more tasks to the
suppliers. Where does FACC Interiors stand in international competition? What are the prospects for
FACC?
Mörtenhuber: The consolidation of
the supplier base in cabin furnishings differs widely as to how far
advanced it is. While the consolidation in the area of cabins for commercial jets is already very advanced, there is still a strong segmentation in the business jet area. However, the trend on both sides is the
same – our customers concentrate
on their core competencies, the
development of the entire plane and
integration. This is why they are
passing over to the supplier more
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complex and comprehensive jobs in
other areas. This development has
been apparent for years and for a
long time FACC has been working
on establishing itself structurally. In
our product portfolio we see ourselves in the upper segment.
take off: China is plainly the emerging market in aviation. FACC is
involved in the ARJ21 project. What
is your assessment of the further
market development in this emerging market?
Mörtenhuber: The significance of
the emerging markets, above all
China, is beyond dispute. It is in the
offing that on the long run a new
balance between the established
players in the West and the emerging ones in the East will materialize. FACC sees itself as an integrative part of the entire market and
showed this quite early with its
commitment to the ARJ21 project.
take off: What are the future
research and development plans in
the interior area?
Mörtenhuber: The continuous further development in all areas, not
only on the component, is a must in
every industry. We always try to
keep an eye on the entire process
chain. In the area of classic R&D we
are concentrating on materials and
processes as well as design innovations which lead to either more efficiency, reduced weight or lower
costs.
take off: As far as the future and
goals of FACC Interiors go, what do
you wish for the long-term future of
FACC?
Mörtenhuber: I can answer this
question objectively, since it is
important for everyone. In my view
the ultimate goal is a long-term and
sustainable perspective in running
our business, and a solid position
among the top three interior manufacturers.
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BOMBARDIER LEARJET
FACC Delivers the 200th Learjet Passenger Cabin
By delivering the 200th passenger cabin for a Learjet 45 XR
(45-376) to Bombardier Aerospace in August 2008, FACC
has reached an important milestone. In Wichita, the 200th
cabin was installed in a business jet which was then delivered to Tiara Air LLC. in Columbus, Ohio, USA. Tiara Air
was quoted at the time of delivery for their aircraft as stating that they “particularly loved the interior of the aircraft”.
>> The long lasting and ever expanding partnership with Bombardier is
an important foundation in the success story of FACC’s interior sector.
This began six years ago when the
Canadian aircraft manufacturer
gave FACC an order to start the
serial production of interiors for the
Learjet 40 and 45XR business jets.
This event would mark the first time
that FACC would enter into the
business jet market segment for aircraft interiors.
In order to support the needs of the
Learjet production line, FACC Solutions, Inc., the wholly owned U.S.
subsidiary of FACC, opened the
Wichita Kansas facility in October of
2005. This facility has been responsible for the final assembly of the
Learjet interior components, delivery of the final product to Learjet’s
receiving personnel, production line
support, and FACC’s liaison for
design and production issues at
Bombardier’s Learjet facility.
David Watson (l.) hands over the 200th passenger cabin for a
Learjet 45 XR to Kevin Wilson, Bombardier (r.)
Since the start of the program, the
high demand for Learjet aircraft in
the business jet market has allowed
FACC to constantly increase the
production rate to around 60 airplanes annually. FACC is responsible for the production of the entire
cabin of both the 40 and 45XR Learjet’s, from the ceiling and sidewall
linings, to forward partitions, to the
exclusive custom cabinets. Based
on this model of success Bombardier further decided to expand its
cooperation with FACC and since
2006 FACC has been the system
integrator of the passenger cabin of
the Challenger 300 business jet. <<
The FACC Solutions, Inc. (FSI) Wichita Team: (From Left to Right)
Blake Jones, Technician; Brian Harvey, Administrations Manager;
Dave Watson, Operations Manager; John Pasquale, General
Manager; Remon Shaw, Technician; Chad Hilton, Technician
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AIRBUS A330/A340:
FACC Started Serial Production of
Flap Track Fairings
Beginning October FACC handed over the first flap track
fairings for an A330-200 to Airbus. The wing components
made of composite materials were delivered to the facility
in Bremen where the wings of the long-range planes A330
and A340 are assembled. Meanwhile, the serial production
of the wing components is in full swing.
The successful FACC team and representatives of Airbus
celebrated the milestone of the first delivery of the flap track
fairings for the Airbus A330/A340 family (Picture above from
left to right): Hannes Schlosser – FACC; Günter Döhle, Peter
Simonis, Christian Schäfer, Kathi Hohn, Alexander Nonnen –
each Airbus; Matthias Hacker, Robert Machtlinger –
both FACC and Bruno James – Airbus)
>> FACC celebrated the program
milestone with a small ceremony at
facility 3 in Ort im Innkreis, Austria,
where the flap track fairings are
being produced. FACC employees
celebrated the start of serial production together with representatives of Airbus Germany.
In September 2007, FACC signed a
contract with Airbus for the production of the flap track fairings for
the Airbus models A330 and A340200/-300, as well as the design and
procurement of the production
tools. The serial production of the
wing components was started after
a mere 12 month development phase. After reaching the monthly rate
of nine ship sets in March 2009,
around 100 additional employees
will be working on the project at
FACC.
Per wing, FACC produces four flap
track fairings of different dimensions. The largest fairing is 6.88 m
long, 0.52 m wide and 0.85 m high.
The aerodynamic fairings contain
numerous technical systems neces-
sary for flight operations, for whose
integration FACC, as a system integrator, is responsible. These include
channels for emergency fuel draining lines.
In addition to supplying the A330
and A340 models, FACC also produces flap track fairings for the Airbus A380. The contract expands the
cooperation with Airbus and enables
FACC to implement their existing
expertise acquired from the development and integration of the technologically complex system for the
wide-body plane A380 in the
A330/A340 program in an optimal
way, and further expand their core
competencies in the area of aero<<
structures.
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Robert Machtlinger
Vice President Structures
FACC AG
“The signing of this contract to
supply all future needed
A330/A340 flap track fairings
further establishes the successful partnership between Airbus
and FACC. FACC can expand its
position as a system supplier for
Airbus for complex surface
structures and once again successfully apply the acquired system expertise.”
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Matthias Hacker
Project Manager
Hannes Schlosser
Program Manager Development
Airbus Structures, both FACC AG
“In only one year after starting
the detail development phase,
we were able to deliver the complete first sample set to Airbus.
This could be described as an
outstanding achievement and an
amazing success of which we
can all be very proud. We are
especially pleased that the entire
FACC / Airbus project team met
all challenges with the necessary
team spirit. The program
management would like to thank
every single person who worked
on the project for the extraordinary support and the good team
work.”
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Bernhard Buchmayer
Group Leader Production
FACC AG
“The decision to produce the flap
track fairings for the A330/A340
planes in the structure facility in
Ort was made on short notice.
That is why it is all the more
remarkable to note the excellent
performance of each individual
on the project team and in production that was necessary to be
able to deliver the first sample to
the customer on schedule. I am
convinced that this team will be
able to manage the upcoming
ramp-up. I would like to thank
everyone who made this success possible.”
Flap Track Fairings: A Core Competency of FACC
The development and production of
flap track fairings are core competencies of FACC AG. As a development and production partner of Airbus, FACC has introduced different
innovations, advanced materials
and improved aerodynamics, which
contribute towards reducing operating costs of the planes. The goal of
FACC is to optimize the structure of
this aerodynamic sophisticated
wing component while simultaneously reducing weight and thus
reducing air drag, noise, weight and
fuel consumption. Through an optimal choice of materials in the component lay-up, the static and dynamic requirements are specifically
fulfilled. Innovative sealing concepts
and advanced paint systems allow
for excellent surface properties and
efficient aerodynamics. Along with
an additional
reduction in weight,
newly designed
mounting and adjusting mechanisms also
guarantee simple assembly and easy access for
maintenance work, as well
as sufficient freedom of
movement during flight.
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NEW BOEING 747-8:
FACC Delivers Wing Components
With the 747-8, Boeing has put a wide-body jet on the market that has the special
advantage of being eco-friendly and very comfortable. The latest model of the 747
family utilizes the most modern technology of the 787 Dreamliner. One of the many
innovations comes from FACC.
>> For the new 747 generation,
Boeing is once again relying on the
tested and approved services of
FACC. In May 2007, the American
airplane manufacturer chose FACC
as supplier for the articulated cove
panel. FACC will produce the components for the 747-8 Freighter and
the 747-8 Intercontinental, just as it
did for the 747-400, and is also
responsible for the development,
production and procurement of the
production tools and metal fittings.
Cost-efficient Production
The new long-range plane is derived from the Boeing 747-400, but
has a fuselage that is six-meters
longer, a new, elegant cabin, wings
that are more aerodynamic, and will
have the modern, efficient engines
of the 787. Due to the enhanced
design of the wings, Boeing has
completely redesigned the articulated cove panel, whereby FACC
engineers, working closely together
with Boeing designers, were able to
provide significant design input and
could already ensure an ideal base
for cost-efficient and high-quality
production in the development phase. “Our years of experience in the
production of these components for
the previous 747-400 model were
definitely an advantage,” stated
Franz Ahammer, project manager at
FACC. However, higher static stress
and the expectation of the customer
to keep the weight at the same level
required FACC to come up with a
new design for the 747-8. “The new
part design is essentially based on
our expertise that we acquired on
the 787 program, in particular on
the spoiler of the long-range airplane,” said Ahammer. One difference between this generation of
the 747 and the previous model is
that the articulated cove panel is
not made of one single fibre glass
panel, but two panels - one out of
glass and the other out of carbon
material. The two-panel concept
instead of the previous design, as
well as the additional use of carbon
fiber, makes for better static performance of the component, thus
meeting higher stress standards.
Testing Phase Has Successfully Begun
In mid-December 2008, FACC completed all preparations for production - the development and procurement of the lay-up tools, the complex assembly and milling equipment and the comprehensive hardware package - and produced two
test parts. In the course of the subsequent test phase, the parts were
used for testing, which proved that
they were failure free. This guarantees that the components will withstand the forces and loads during
flight. At the same time FACC is
already producing the first article
components and is performing all
activities towards part qualification
by the customer and the aviation
authorities. The delivery of the parts
to the Boeing plant in Everett,
“FACC has been a supplier for Boeing’s 747 programs since 2000. Due to the positive feedback
during years of collaboration, Boeing has once
again chosen FACC as a partner, this time for the
new 747 generation. Our design input has resulted into a cost-efficient production as well as a
high-quality product.”
Franz Ahammer
Project Manager, FACC AG
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Wash., pre-assembled by FACC
and ready to install, will begin in
early 2009. “According to the new
contract for the 747-8, FACC is also
responsible for the installation of the
entire hardware package and will
deliver a ready-to-install panel,” is
how Franz Ahammer explains the
difference between this and the
conventional component of the
747-400 and also emphasizes the
advantages of the extended cooperation. “This way Boeing saves
time in the final assembly of the airplane. FACC, on the other hand,
profits from a much higher added
value.” In spite of the substantial
amount of metal parts, the component of over 3.3 meters long and 2
meters wide weighs only 89 kilograms and thanks to the optimized
composite laminate, FACC was able
to meet the requirements of higher
stress at the same weight. The articulated cove panel is an aerodynamic wing panel that covers the area
between the wing surface and landing flaps on the upper surface of
the wing adjacent to the fuselage.
During flight and particularly when
deploying the landing flaps, the
component is exposed to a multitude of forces, which makes the high
load capacity of the component
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necessary.
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New Eco-friendly Boeing 747-8
The Boeing 747-8 Intercontinental
and the 747-8 Freighter are the
new high-performance members
of the 747 family. The model number 747-8 was chosen in order to
emphasize the technological similarities of the 787 and the new
747. The 747-8 utilizes the innovative technologies of the 787 to
considerably improve the efficiency and the functionality of the 747400, at the same time improving
fuel consumption and reducing
emissions and noise. The newest
family of 747 planes complies with
the wishes of the airlines for a passenger plane that serves the mar-
ket for planes with 400 to 500
seats.
Boeing began production on
the first 747-8 Freighter in August
2008. The first freighter will be
delivered to Cargolux the third
quarter 2010 following assembly
and flight test. The first 747-8
Intercontinental passenger jet delivery is planned for the second
quarter of 2011. Since the program began in November 2005,
eleven customers have so far
ordered 106 Boeing 747-8 Intercontinentals and Freighters.
Technical Characteristics Boeing 747-8
Seating
Engines (Thrust)
Maximum Takeoff Weight
Range
Cruise speed
Wing span
Length
Height
467 passengers in a three-class configuration
GEnx-2B67 (66,500 pounds)
975,000 pounds (442,255 kg)
Intercontinental – 8,000 nmi (14,815 km)
Freighter – 4,420 nmi (8,185 km)
Mach 0,855 (Intercontinental)
Mach 0,845 (Freighter)
224 ft 7 in (68.5 m)
250 ft 8 in (76.4 m)
64 ft 2 in (19.5 m)
takeoff
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TAKEOFF
takeoff
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MILESTONE:
1,000th Outer Bypass Duct for a BR710
The long and successful partnership between FACC and the engine manufacturer
Rolls-Royce is celebrating a significant milestone: In September FACC officially
handed over the 1,000th outer bypass duct for a BR710 engine to Rolls-Royce. The
outer bypass duct was delivered to the Rolls-Royce plant in Dahlewitz, Germany.
>> Since October 2001, FACC has
been producing these weightsaving, sound-absorbing components for the BR700 engine family.
Just a few months ago Rolls-Royce
further expanded its cooperation
with FACC by awarding the company with a contract for the supply of
the outer bypass ducts for the
BR725 – the newest of the BR700
engine family, still in the development stage. This new contract
boosts FACC’s market leadership in
the development and production of
engine nacelle components using
advanced composite technology.
In turbofan engines, the outer
bypass duct channels the outer air
flow (bypass flow or secondary air
flow) past the core engine. The fan
works like a sheathed propeller and
produces around 80% of the propulsion, depending on the model.
Innovative Technology
for Efficient, Eco-friendly
Engines
For years, and in cooperation with
engine manufacturers, FACC has
been intensively researching the
area of engine and engine nacelle
components. The focus of the R&D
is on improving the efficiency and
environmental soundness of new
engines that feature reduced fuel
consumption and produce less noise and pollutants. By using more
composites in engines, the total
weight and fuel consumption of the
aircraft can be reduced. Due to their
design, their material properties and
the processes used, composite
components can significantly minimize the noise levels of planes. In
the production of engine nacelle
components, FACC uses innovative
manufacturing processes that are
unique in Europe, among others a
special technology for the processing of acoustic, noise-absorbing
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surfaces for engine nacelles.
Arrived in the four-digit range: The FACC team celebrated together with representatives
of Rolls-Royces the delivery of the 1000th outer bypass duct for a BR710 engine.
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takeoff
EVERYONE WALTZ!
The Viennese Opera Ball
Coffee houses, the Sachertorte and the Opera Ball – three things that inevitably are
connected with Vienna. On the last Thursday of the carnival season the social event
par excellence of the Austrian ball season is celebrated: the Opera Ball.
>> Once a year, the stage and stalls
of the State Opera House are turned
into a huge dance palace for one
night. The Viennese Opera Ball,
which was first held in 1935 as a
charity event, is today among the
largest and most successful dance
events that is attended by local and
international celebrities and VIPs.
Whether they are rich, beautiful,
important or just there, the elite
from politics, business and culture
meet there and mingle with a dabbling of stars and starlets.
The ball is opened with the classic
Fächerpolonaise, whereby around
160 dance couples from the youth
committee enter the ballroom to the
melody composed by Carl Michael
Ziehrer. After obligatory song and
dance performances, it is traditional
that the dance floor is turned over to
the ball attendees with the com-
mand coined by Johann Strauss:
“Everyone waltz!”, and the guests
twirl in three quarter time in the
nostalgic ambience of the Opera
House.
York and Dubai, as well as in Istanbul, Zagreb and Kuala Lumpur, partly sponsored by the Vienna Opera
Ball in order to guarantee the origi<<
nal Viennese flair.
The Opera House during
the Ball
During the ball the Viennese State
Opera House is open from cellar to
attic – fully accessible to all. In the
Schwind foyer above the main formal staircase the Casinos Austria
install a casino every year, expressly
for the ball guests. Myriads of
restaurants, champagne bars,
oyster bars and even a wine tavern
cater to the guests.
A Ball Dances around
the World
The Viennese Opera Ball exists not
only here in Austria. Viennese balls
are held in many cities such as New
The Vienna State Opera, with its nostalgic atmosphere is
the venue of the annual Opera Ball.
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A MEMORABLE DAY:
On Friday, November 28, 2008 the ARJ21 took to the skies, a key step in China’s ambitious aviation program.
With value-added innovations, FACC is proud to support the ARJ21 commercial aircraft program in delivering
a high-quality passenger cabin.
Congratulations to COMAC and ACAC
for the successful first flight of the ARJ21!
FACC AG
A-4910 Ried/Austria, Fischerstraße 9, P.O.Box 192
Tel. +43 / 59 / 616 - 0, Fax +43 / 59 / 616 - 81000
e-mail: office@facc.at, www.facc.co.at