"Take off" - Issue 2/13

The FACC Information Magazine
Issue 2 | 13
Creating Future
page 4 - 5
Next Generation Engines
page 18 – 19
Engineering Excellence
page 21
contents
4–5
Creating Future
FACC’s Technology Center and Test Center
13
Design optimized!
21 Translating sleeves for Boeing 787-9
The formula for
“Engineering Excellence”
FACC as a partner in an Airbus pilot project
6–7
FACC Open5
14 – 15 Powerful
Inauguration of FACC’s Technology Center
and Test Center
Nacelle Components &
Bypass Ducts
21 A350 completed maiden
flight
Each of FACC’s three divisions was on board
8–9
Spoilers and ailerons
for E-Jets E2
16 – 17 Insider
Continued Partnership &
Best for West
First Aerostructures contract awarded
by Embraer
18-19 Next generation Engines
10 – 11 Production with new
Technologies
FACC develops new annulus fillers
in a collaborative effort
22 The Prize for Excellence
Excellent Supplier Award 2012
22 Award-winning!
FACC becomes first frontrunner enterprise
in Austria
FACC delivers flaps for Airbus A321
12
Split and save big!
20 Best Practice as a
Win-Win Situation
FACC makes split scimitar winglets
for Boeing 737NG
FACC project to optimise assembly line
for luggage compartments
23 Flying without wings
Fascinating Four Hills Tournament
23 Panalpina Logistics
Centre for FACC
& Maiden Flight of
Bombardier CSeries
IMPRINT:
Published by: FACC AG, Fischerstraße 9, A-4910 Ried/Austria. Editorial
staff: Walter Stephan, Robert Machtlinger, Andrea Schachinger. Layout & graphic concept:
Reichl und Partner, Linz. Photos: Embraer, Alenia, APB, Boeing, Airbus, Pratt & Whitney,
Bombardier, Superjet International, Rolls-Royce, Manfred Lang Klagenfurt, Oskar Pointecker
Mehrnbach, Alois Furtner Gurten, FACC Ried.
The front cover shows an FACC employee assembling a translating sleeve for the
787 Dreamliner.
Ta k e off, Is s u e 2 /1 3
An autumn of soaring
to new heights!
Dear readers,
This has been an autumn packed with
action. For the first time ever, the maiden flights of two computer designed
aircraft models took place in one and
the same week. September 16 saw
the long awaited inaugural flight of the
Bombardier CSeries which marked the
launch of a new generation of aircraft
in the 130 to 160 seat category. On the
following day, the Boeing 787-9 took to
the skies. Both only three months after
the maiden flight of the Airbus A350
XWB. And all of these aircraft feature
components made by FACC.
On top of that, still in the same week,
the flight test aircraft of Aviation Partners Boeing, a 737-800, received the
“go ahead” from the Federal Aviation
Authority. Consequently, things are
looking good that it will be possible to
still obtain the approval in Q4 of 2013.
Using the new split scimitar winglets
(see article) developed with FACC involvement, airlines are now able to take
the performance of their aircraft to yet
another level. By the way, in 2014, we
will deliver our 5000th pair of winglets.
This makes FACC the global leader for
these fuel saving components.
“editorial”
No screenwriter could have planned it
better: the week of maiden flights also
saw the inauguration of our new Technology Center and Test Center. Building
on this new hub of our international research, development, and manufacturing network, we are all set for the challenges of the future. We will be actively
and significantly involved in fast-paced
development processes and contribute
to our customers’ success. I am certain
that, with our committed and competent people at FACC AG, we will fully
live up to this claim.
Yours,
And, going forward, the pace of innovation will continue to accelerate. In fact,
our customers have scheduled 22 further maiden flights for the next five year
period. By comparison, there were only
14 during the last decade.
This means that:
• there will be plenty of work for the development departments. They must ensure that the new programs will indeed
help achieve the promised 15-20% in
fuel savings.
• our customers will also be facing a
rougher competition for shares of a
growing market. As innovation turnaround becomes faster, the necessity to
become more efficient will increase –
from the development stage to financing the required development effort.
Walter A. Stephan
CEO of FACC AG
pa ge 2–3
The new buildings have now been completed. This is
where, going forward, FACC will bundle its research &
development efforts and is therefore all set for the dynamic
corporate growth and the challenges of the future.
Data, facts, figures.
DELTA was in charge of architecture, planning, and
local building supervision. Within 14 months, the
Technology Center and the Test Center were built
on a 50,000 m² plot of land in St. Martin, directly
adjacent FACC’s Sites 2 and 3. With building costs
totalling EUR 22 million, this project is a part of
FACC’s ongoing R&D investment program (total
volume: € 96.8 million). This is where, from now
on, 500 of staff members will actively participate
in shaping the future of our organisation. Through
this project, FACC again demonstrates its role as
a trendsetter and flagship enterprise of the region.
Ta k e off, Is s u e 2 /1 3
FACC’s Technology Center and Test Center
Creating Future
Faster development processes,
innovative manufacturing concepts.
The new Technology Center serves as FACC’s R&D
hub. It collaborates closely with FACC’s engineering
offices in Germany, Slovakia, the U.S., Canada, China,
and India. This helps speed up and streamline development processes. In addition, the engineering departments of FACC’s Aerostructures and Interiors divisions
are now both accommodated in the new building. The
adjoining Test Center constitutes one of the most cutting-edge centres for analysing, testing, and certifying
of fibre composite materials and components and will
also contract its services out to other businesses.
Modularity, flexibility, identity.
The architecture lives up to the requirements for
groundbreaking research. Its open design and
short distances encourage interdepartmental
collaboration. Key principles in planning included
a strong practical focus with high flexibility and
modular space structuring solutions. This is why
the office and workplace concept was prepared
jointly with FACC staff members. Combinations of
materials and light effects result in a special atmosphere. Furthermore, the aim was to create modern
architecture that aptly mirrors the identity of the
enterprise.
pa ge 4–5
FACCOPEN
5
Inauguration of FACC’s Technology Center and Test Center
Rachel Bahr & Andreas Roder from
EMTEQ, the innovative supplier of
avionics, lighting, and
cabin comfort solutions.
Demonstrating their keen
eyes for every detail: Sonny Discar
& Randy Peters, UTC.
›
›
Exchanging ideas with Boeing:
Donald M. Sears, Director – Structures
North America/Europe Supplier Management, Boeing; Walter Stephan, FACC
CEO; Michael A. Underwood, Boeing Site
Leader BCA SM Europe, Boeing
In talks with Airbus: Andreas Furthmayr,
VP Aerostructures, FACC; Walter
Stephan, FACC CEO; Mark Haisman, VP Head of Procurement Aerostructures Wing
Commodity, Airbus; Robert Machtlinger,
FACC COO
›
›
‹ “Growth through innovation has
secured and will continue to secure
FACC’s long-term competitiveness”,
stressed FACC’s CEO Walter A. Stephan
in his inaugural address.
Ta k e off, Is s u e 2 /1 3
September 19, 2013, saw the grand opening of FACC’s fifth
site in Austria, celebrated under the motto “Open5 – Creating
Aerospace Technologies”. Various illustrious guests from the
worlds of business and politics were in attendance.
http://www.facc.com/en/News/
Events/Opening-of-the-new-FACCTechnology-Center
Saralaya Prakash &
Lingasheddar Nanjundesh, TAAL
›
‹
The design of the offices was met with
great acclaim from Etienne Ravaud, Head
of Wingboxes and Wingtips Aerostructure Procurement, and Mark Haisman,
VP - Head of Procurement Aerostructures
Wing Commodity (both from Airbus)
Walter Stephan, FACC CEO; Christoph
Schöndorfer, Managing Director, etc. Prüf
und Test GmbH; Hermann Filsegger,
FACC Director Product Development
Aerostructures; Gerhard Mörtenhuber,
FACC EVP Interiors; Robert Machtlinger,
FACC COO.
He came from afar: Huang Hang from
XAC, the Xi`an Aircraft Company,
examining the installed testing facilities, in
the company of Kurt Pieringer, FACC VP
Operations Aerostructures.
›
‹
One innovative enterprise visiting
another: Mike Stowell, EVP, Chief Technical Officer and William Ashworth, CEO,
from Aviation Partners Boeing. The company’s winglets contribute substantially
towards improving fuel economy.
pa ge 6–7
Spoilers and ailero
First Aerostructures contract awarded by Embraer
The new regional aircraft family comprises three
models. With a capacity for 70 to 130 seats the
next E-Jet generation will be more efficient and
quieter in operation than their predecessors.
FACC was entrusted with the development and
production of the spoilers and ailerons. The
contract signed in June 2013 is for the lifetime of
the aircraft.
From Interiors to Aerostructures.
The E-Jets E2 spoilers and ailerons contract marks a significant expansion of FACC’s relationship with Embraer. With
this award, FACC was able to extend its cooperation with
the globally successful Brazilian aircraft manufacturer - so far
limited to the supply of interiors products - into the aerostructures sector.
Specialist for Wing Moveables.
“FACC is excited to expand its long-term experience as a
Tier-1 design and build supplier,” said Andreas Furthmayr,
FACC Vice President Aerostructures. “As a leading specialist
in composite wing moveables, we are well-positioned to deliver innovative design solutions. No other company has more
experience than us in managing the integration of composite
spoilers and ailerons according to the latest state-of-the-art
technology.”
Comprehensive FACC experience
applied.
In its cooperation with Embraer FACC brings in its extensive
expertise in composite solutions. The engineering Joint Definition Phase (JDP) is under way and a team of FACC design
and stress engineers is on site at Brazil. The composite spoilers and ailerons will be a vital element in this next generation
E-Jets E2 aircraft family attaining specific
goals for an aerodynamically advanced wing, reduced
fuel burn as well as lower emissions with maximum efficiency. FACC’s
systems are designed to be
lightweight and cost-efficient.
Innovative connecting elements and the
fundamental spoiler and aileron functions are integrated into
one ready-to-be-delivered unit. FACC supplies six spoilers
and one aileron per aircraft side. Delivery of the first parts
under this contract is expected to take place in Q1 2015 to
support aircraft entry service in 2018.
•m
E-Jets E2 – Evolutionary lead
Embraer announced the launch of its new commercial
aircraft program at the Paris Airshow mid June 2013.
The second generation of the regional jet family will
comprise three airplanes – E175-E2, E190-E2, and E195-E2
offering leading-edge aircraft with a capacity for 70 to 130 seats. The
application of advanced technologies for engines, wings, and avionics distinguishes the E-Jets E2 by providing airlines commonality with current
E-Jets, while resulting in double-digit reductions in fuel consumption,
emissions, and noise and maintenance costs.
Ta k e off, Is s u e 2 /1 3
-J
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•
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• ai
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t
n
a
ons for E-Jets E2
“
We are proud that Embraer has selected FACC as supplier in this important
next generation aircraft program. With
our experience we will contribute to the
development of the game-changing, highly efficient E-Jets E2 family.
Walter A. Stephan
(CEO of FACC AG)
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”
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pa ge 8–9
Production with new
technologies
FACC delivers flaps for
Airbus A321
The A321 has been in production for several years. This stretched version
of the highly popular A320 family seats up to 220 passengers. In view of
the long-standing excellent cooperation within the scope of various Airbus
programs, FACC was awarded the contract for the production of the flaps
for the A321. Recently, in August 2013, FACC delivered the first flaps
manufactured using brand-new technologies.
Precision and efficiency through automated tape laying.
Ta k e off, Is s u e 2 /1 3
New technology “Hot Forming” employed
in series production at FACC.
The worldwide demand for the
A321 has been taking off well. FACC
supplies its flaps.
Entry into the primary
structures segment.
By signing the contract in April 2012, Airbus
transferred the production of the flaps for the A321
to FACC. For FACC, this contract means the successful entry into the primary structures segment at a globally leading
aircraft manufacturer. As a result, FACC continues to build
its reputation as a specialist for wing components. For this
purpose, FACC also invested in new technologies, moving its
production technology another step forward.
Automated tape laying.
For suppliers to the aeronautics industry, ultra-high efficiency
is a key factor that, in the competitive environments of the future, will still continue to gain in importance. Therefore, FACC
purposefully expanded its automation capabilities through its
new machine that has been in operation since March 2013.
Olaf Koch, from FACC’s Research & Development Engineering unit, said about the recently launched technology,
“composite components consist of several layers of material
which, in this case, is unidirectional tape. During automated
tape laying (ATL), layers are placed on top of one another in
various directions by the machine. Subsequently, the completed laminate is high-precision cut to the required contours.
The resulting benefits are higher productivity and outstanding
reproducibility. ATL is ideal for simpler and large geometries
as well as for high-throughput components, while
more complex assignments and components will
continue to require manual layup. On the bottom
line, however, this automation helps our customers
obtain efficiency advantages in many series production projects”.
Hot Forming.
Another new technology employed in the series production of
A321 flaps pertains to the following manufacturing step. During hot forming, the flat preform produced by ATL are given
their final three-dimensional shape by applying heat and pressure as well as by using a core and a flexible forming pad.
The new, cutting-edge facility, custom-tailored for FACC with
respect to the components to be manufactured, the process
parameters, and the data management, was engineered and
delivered by Austria-based Fill in record time.
Added value for the region.
FACC purchased not only the new facility itself, but also the
pertinent tools, molds, and devices from nearby regional suppliers. The quality, flexibility, and speed of, and the uncomplicated collaboration with regional businesses once again
justified the trust placed in them. Plus, there is a positive spinoff effect: also the region benefits from the innovation and
investment steps taken by the aerospace supplier.
pa ge 10–11
Split and
save big!
FACC makes split
scimitar winglets for
Boeing 737NG
The maiden voyage of the flight
test aircraft with fitted split scimitar
winglets, which took place on Tuesday,
July 16, 2013, was a full success. Now, the
industrialization for the series production of these
innovative aerodynamics-enhancing components is nearing completion. Also the existing winglets on 737NG series aircraft
will be converted into split winglets. And by opening new offices in
Seattle and Wichita, FACC underscores its commitment to customer
proximity.
Benefits of split scimitar
winglets.
The aerodynamically shaped wingtip that includes a downward angled
ventral strake enhances the lift of an
aircraft. This increases fuel economy,
range, and payload capacity.
Under a contract awarded by Aviation
Partners Boeing (APB), FACC is the
designated supply partner for the new
winglets. Building on the experience
gained from supplying more than 4,000
conventional winglets (blended winglets)
to Boeing, the team from FACC has
again demonstrated its capabilities and
expertise in this structures segment
of the aerospace industry. The pro-
ject kicked off in mid December 2012.
FACC has been in charge of development, design, calculation, modification,
and production. The first flight test unit
arrived at Seattle right on schedule at
the beginning of July.
Customer proximity at
FACC.
A large part of the development efforts
were performed in Seattle. To this end,
FACC AG opened its own engineering
office in Boeing’s home city. By doing
so, FACC consistently follows through
on its strategy of worldwide customer
proximity and of promoting internationalization. In addition, FACC established
a manufacturing operation at Wichita,
Kansas. There, up to 30 staff will be
converting existing NG winglets into
split scimitar winglets.
Boeing 787 Chec
THE BOEING
787-8 is the fir
st model of Bo
eing’s
Dreamliner fam
ily. This super-e
fficient 56 m (18
4 ft)
long jet airliner
seats up to 25
0 passengers.
With
total orders fo
r the 787-8 at
498 planes, it
is currently the mo
st popular of
Dreamliner mo
dels.
FACC supplies
spoilers, lower
bonded panels,
horizontal stabilize
r forward box
and trailing ed
ge panels, translating
sleeves, and en
gine componen
ts.
THe Boeing
787-9 is the sec
ond member of
the
super-efficient
Dreamliner fam
ily, “stretched“
6 m (20 ft). Th
by
is provides the
necessary extra
space
Ta k e off, Is s u e 2 /1 3
klist
to seat up to 29
0 passengers. Its
successful first
flight took place
on September
17, 2013. FACC
supplies spoilers
, lower bonded
panels, horizon
tal stabilizer for
ward box and
trailing edge pa
nels, translating
sleeves, and engin
e components.
The Boeing
787-10 is the
third and longe
st
member of the
787 family. Ex
tra length adde
d
to its fuselage
makes this mo
del 68 m (223
ft)
long and increa
ses its seating
capacity to mo
re
than 300 passe
ngers. Again, FA
CC componen
ts
will be part of
the package.
Scalloped
Chevron. Th
e new design includes
“chevrons“ as
were introduced on the pr
evious model.
TRANSLATIN
G
SLEEVES.
Reverse
thrust is a me
thod to assist
jet aircraft
in slowing do
wn upon touc
hdown. The
engine’s exhaus
t air is diverted
in a forward direction
by extendable
flaps/doors.
FACC is a spec
ialist for the sle
eves including the thrustreverser doors
and the connection element
s.
Design optimized!
Translating sleeves
for Boeing 787-9
Continued trust.
FACC’s customer under this contract
is UTC Aerospace Systems – Aerostructures based out of Chula Vista,
CA U.S. This tier-1 supplier of Boeing
is in charge of developing and manufacturing the engine nacelles for the
787 series. FACC already supplied the
translating sleeves for the first model
series, that is, the 787-8. In 2010, this
contract was extended to also encompass the new 787-9 model. FACC has
been assigned a far-reaching scope of
tasks, from the design, development,
and production of the components, to
the design and procurement of the production tools and to testing, qualifying
and certifying the first article parts.
Launch Schedule met.
“One of the challenges we were facing
in the execution of this project was the
short time frame between the start of
Boeing 787-9 aircraft can be fitted with two
different engine options. In the form of ready-toinstall systems, FACC supplies the translating sleeves used
Rolls-Royce Trent 1000 and General Electric GEnx jet engine cowling. The first translating sleeves have now been delivered, and series
production has started.
the design phase and delivery”, explained Christoph Zaunbauer, Director
Nacelles Programs at FACC. Bernhard Schöpf, Program Manager Boeing
787 Translating Sleeve, went on to say:
“Thanks to the excellent collaboration
between customers, suppliers and our
team, we were able to deliver on time a
full-fledged, ready-to-install system featuring genuine innovations”.
Fuel economy.
For component design, FACC drew
directly on its wealth of previous experience and expertise gained when
developing the translating sleeves for
the 787-8. Further developments in de-
sign, materials, and processes allowed
FACC to optimise its components and
achieve another reduction in weight.
Through product innovations such
as the “scalloped chevron”, the aerodynamics of the rear edge of the exhaust nozzle were optimised. The outcome is improved fuel economy. This
will in turn reduce operating costs and
enhance the efficiency of flight operations. At FACC, however, any success immediately serves as the starting
point for further development. Therefore,
FACC’s engineers are now busy working on further manufacturing process
upgrades and reductions of costs and
weight.
pa ge 12–13
FACC Division Engines & Nacelles
Nacelle Components
for Airbus A320neo
As an upgrade of the successful A320 family, A320neo aircraft raise the bar in terms of fuel economy,
increased range, but also optimized operating costs. The A320neo (new engine options) family features
two different engine options and large wingtip devices known as Sharklets. The delivery of FACC components has been ongoing.
FACC Nacelle Components.
Strong Team Effort.
FACC supplies innovative components made of carbon-fiber-reinforced plastic
materials. This groundbreaking technology contributes substantially to reducing the
noise produced in the air inlet of CFM International’s LEAP-1A engine.
The time schedule was a sporting challenge. The contract was awarded a
mere 6 months before the scheduled
initial delivery. Within these 180 days,
FACC developed the manufacturing
concept, designed and made all tools,
conducted all manufacturing
tests, and produced
the first parts. Right
on schedule, on
the originally agreed
date (May 13, 2013), the
first shipset was dispatched to Nantes.
At the same time, all qualifications were
performed.
Says project manager Wolfgang Mayrhofer, “FACC has once again demonstrated great flexibility and reliability
in an excellent team effort across all
departments involved. A big thankyou to the motivated and dedicated
team who made this possible.
Even in the face of tremendous
time pressure was it possible to
cost-effectively achieve the industrialization for a stable series
production”.
Team Spirit
Performance
output
Respect
A team for customers to count on: FACC’s project
team at the initial customer delivery
Ta k e off, Is s u e 2 /1 3
Bypass Ducts
for Pratt & Whitney PW PurePower®
For more than 10 years Pratt & Whitney, one of the world’s leading engine manufacturers, has been collaborating with FACC on the development and manufacture of bypass ducts. With the latest engines that
are developed for business jets, the enterprise relies on FACC again.
In March 2013, after a development
time of only 12 months, the first outer bypass duct set was delivered to
Québec for the engine PurePower ®
PW800. This tight time schedule could
be implemented only by practicing socalled “concurrent engineering”, which
requires a very good coordination between the customer and the supplier
in terms of engineering, schedules and
costs. Inside the group, Pratt & Whitney Canada is the competent unit for
smaller, highly efficient engines used
in business jets, regional airliners, and
helicopters.
required the know-how of FACC, which has been gained in the course of developing several PW bypass duct types already produced in series.
The significant feature is the aerodynamically and acoustically optimized inner surface ensuring both an efficient and thus fuel-efficient application at reduced emissions and a considerable noise reduction to remain below future
noise limits. Currently, the engines are set up at the FACC premises. Various
detail configurations for load tests and acoustic tests are fabricated. The resultant optimum variant will go into serial production.
Strong, quiet, and aerodynamically optimized.
The bypass ducts developed by
Prat t & Whitney with the collaboration of FACC cover the outer air
stream and have to withstand high
loads while featuring high wear resistance as well as the lowest possible weight. The new bypass duct
variant is the biggest one FACC has
manufactured so far. Its complexity
Output
Respect
Performance
Team Spirit
Next generation bypass ducts:
Pratt & Whitney design developed with the
collaboration of FACC. The engines will be
used in business jets.
pa ge 14–15
FACC Division Interiors
Continued Partnership
Cabin for Bombardier Challenger 350
Bombardier has taken its successful Challenger 300 model to another level. The
new Challenger 350 impresses with a range of 5,900 km, a cruise speed of 0.80
mach, and a climb rate that gets the new super midsize jet for 11 passengers to an
altitude of 41,000 feet in only 18 minutes. Its comfortable luxurious cabin comes
from FACC.
Long-Standing Partnership.
FACC supplies the entire cabin, from the galley
to the curtains, from the baggage compartment
to the partition walls including the door mechanism. The design is based on the cabin of the
Challenger 300. Since FACC has been making
cabins for the CH 300 for years, it was possible
to directly apply the standards for workflows and
processes. The resulting efficiency advantage
Ta k e off, Is s u e 2 /1 3
has been of equal benefit to both partners. The
first shipset was delivered as slated at the end of
August. At the moment, the initial installation at
Bombardier is ongoing. The plan is that, starting
from the beginning of 2014, FACC will be delivering 5 shipsets per month. Bombardier has
already secured firm orders for more than 115
Challenger 350 jets, plus purchase options for
another 125.
Best for West
Cabins for Sukhoi SSJ100
Since its inception, the Russian SSJ100 (Sukhoi Superjet) has been
developed as a regional jet for the global market. A large number of
international companies have been involved in this project. Hence,
it is no coincidence that the cabin interiors of those aircraft that are
destined for the Western market were designed in Italy – and are
manufactured by FACC.
International Cooperation.
P i n i n f a r i n a , a c o m p a ny b a s e d i n
Nor thern Italy, created the design.
The engineering was completed at
the Alenia plant in the south of Italy.
And, FACC was selected to manufacture these cabin interiors. Staf f
f rom FACC pa r tne re d w ith A le nia
during the development ef for ts at
th e i r s i te i n N a p l e s. T h e n, FAC C
c o m p l e te d t h e e n t i r e i n d u s t r i a l i zation including toolmaking within
less than 5 months. Meanwhile, the
first cabins have already been installed. The place of installation is at
S u p e r j e t I n te r n a t i o n a l i n Ve n i c e.
Since September 18, two SSJ100 of
the Mexican airline Interjet have been
operational in commercial ser vice.
FACC demonstrated again that coordination and cooperation are among
its fortes.
Weight-Saving Lavatories.
Within the scope of this contract,
FACC has, for the first time, developed and qualified complete lavatories. Based on the specifications
provided by Alenia, this development
also save s weight. T he toilet wall
with two directly mounted seats for
flight attendants is made of carbon,
instead of the standard aluminium.
A n d, FACC n ot o n l y s u p p li e s th e
complete cabin panelling, but also
the cargo compar tment lining. The
latter for all SSJ100 jets – “Eastern
and Western” versions.
pa ge 16–17
From a simulation to
the actual component
Next Generation Engines
FACC develops new annulus fillers
in a collaborative effort
Under the EU-funded research program CleanSky®, FACC leads a consortium with Rolls-Royce plc. and the University of Applied Sciences
Rapperswil to develop composite rotatives for “Sustainable and Green
engines” (SAGE). Focus part is the so called Annulus filler, a
rotating part located between the fan blades.
Ta k e off, Is s u e 2 /1 3
Composites save weight.
Excellent result.
The main parameter for fuel efficiency and performance is the
diameter of the engine. Larger diameter allow higher bypass
ratios, increasing the flight performance of the engine, but
also add massively to the engine weight. Composites help to
reduce the weight penalty and act as an enabler for next generation aircraft engines.
A team of specialists from FACC Engineering Solutions Vienna, the R&D and the tool development department – supported by Rolls-Royce plc. and the University of Applied Sciences
Rapperswil – have created a part not only to withstand the
requirements, but also put focus on manufacturing-friendly
design to be able to deliver very high part quantities in an appropriate process.
FACC’s developments make engines lighter and more efficient.
Annulus Filler (in white) in a static test jig
Annulus Filler – purpose and objectives.
Main task of an annulus filler is to direct the airstream to the
fan blades under rotating conditions. The current solution is a
metallic part, a machined forging with relatively high weight,
and elevated costs.
While the part weight is about half a kilogram, the part needs
to bear loads up to 2500kg through centrifugal forces, even
under gravel impact conditions. These requirements posed
an enormous challenge on FACC’s Research and Engineering
departments, especially when considering the time frame:
less than 1,5 years from the first concept to the manufacturing of the final prototype.
Extensive design work (15 different design concepts) and
complex simulation (FE- stress analysis, fill simulations) led by
Balint Koller and Dr. Christof Obertscheider and effective process design (first shot right, capable of a high volume serial
production) led by Gazmend Braha brought an outstanding
result. The current filler is over 40% lighter than its predecessor, less expensive and even compatible with the existing
attachment featu1res, so a retrofit to in-service engines is
possible. With this impressive achievements, FACC AG contributes to a more eco-friendly aircraft design by intelligent
design & manufacturing.
The prototype currently undergoes extensive
ground testing,
before being
mounted on a flying test engine in 2014.
The patent for part and production
method is pending.
Annulus Filler: FACC innovation
for greener engines
pa ge 18–19
Training
Shopfloor
1
Analysis
2
Optimization
Transparency
Quality at work
3
Best practice
Logistics
Management
Best practice
as a win-win situation
FACC project to optimise assembly line for luggage
compartments
FACC manufactures the overhead stowage compartments for the Airbus A320, A350, and A380. The
objective of our “New Layout” project is to make good things even more efficiently and better. Our
self-imposed task is to design an efficient industrial cutting-edge assembly line that will also be recognised as the best practice within the aerospace industry. This will benefit the customer – but also FACC’s
employees, the project team, and the enterprise as a whole.
The project.
A small core team analysed the flows, using value stream
mapping methods. A value stream depicts all components in
the flow. This reveals where a component flows into another,
that is to say, where component assemblies are created. In
addition, the ratio between value-adding and non-value-adding times is indicated. Based on the findings, the final project
team was put together including experts in planning, manufacturing, logistics, and quality assurance. In preparatory
seminars, the specialised technical topics were combined
with drills in interaction and interdisciplinary collaboration in
order to internalise as a team the significance and the impact
of intensive team work, temporary leadership, or appreciative
communication.
Focus.
The topics these optimization efforts aim at are wide-reaching. They focus on achieving transparent manufacturing,
consistent shopfloor management, powerful and reliable
Ta k e off, Is s u e 2 /1 3
logistics, high quality at work, and effective induction training
programmes for staff members. The work packages have
been defined and are scheduled based on the end of the project being in April 2014. Each week includes one project day.
Win-win situation.
In addition to the establishment of best practice manufacturing, the project also strives to achieve a triple win situation.
For the staff members, the feel-good factor is to be enhanced
by providing a work environment that is characterised by continuity and smooth, troublefree workflows. For the enterprise,
streamlined manufacturing operations in turn ensure a high
degree of continuity and consistent workflows. This increases
predictability, transparency, and, consequently, also productivity. And the team learns to live with planned workflows. The
degree of improvising decreases and is superseded by routine. Such routine activities, which staff members master reliably and with great ease, help free up capacities. This allows
us to increase our focus on innovations and upgrades.
1+1=1
The formula for
“Engineering Excellence”
FACC as a partner in an Airbus pilot project
The A350-900 has successfully completed its maiden flight. The production of the A320, A350, and A380 has been progressing successfully. Great
efforts are being made to press forward with new developments such as
the A350-1000 or the A320neo. This requires a highly efficient value chain.
To this end, the cooperation between the manufacturer and its suppliers
constitutes an essential factor. Based on the formula of “two cooperating
partners deliver unique results”, Airbus and FACC have, in a pilot project,
been perfecting the recipe for the “Engineering Excellence” of the future.
Extended Enterprise Program forms the foundation.
In business economics, the term extended
enterprise refers to the concept that an
enterprise does not operate on its own in
its efforts to achieve success, but rather
within a network of partnerships. Airbus has
launched such an “Extended Enterprise Program”. By cooperating with select suppliers
and with the support of a renowned strategy
consultant, the target is to achieve sustainable improvements for the value chain of the
future.
Engineering competence.
Because of the long-standing good cooperation, FACC was chosen as the partner
for the “Engineering” segment. The project
kicked off with a joint analysis of the relevant
processes as well as of the requirements
and challenges which top performances
demand and pose. Causes, interfaces,
malfunctions, but also the outstanding positive examples were subjected to thorough
examination, ambitious goals were set, and
the criteria used to measure success were
defined. Solutions for the jointly identified improvement potentials along the engineering
process were elaborated.
The measures concern both the implementation efficiency and the quality and standardization of performances.
The strong collaborative approach led to a
general paradigm shift. In the future, analyses, design modifications, and implementations will be carried out jointly by Airbus and
FACC from a position as equal partners.
A350 XWB
completed
maiden flight
Each of FACC‘s three
divisions was on board.
In June, the great day arrived.
The A350 XWB completed
its four-hour maiden flight,
kicking off a 14-month series
of testing. Airbus has already
received orders for more than
700 of this new aircraft. And
each of FACC‘s three divisions has contributed towards
the success of this new longhaul airliner. FACC Engines &
Nacelles is delivering translating sleeves and engine components, FACC Interiors door
covers, smoke detector panels, and baggage compartments, and FACC Aerostructures spoilers and winglets.
Condensed expertise.
FACC will also support Airbus in the preparation of a general guidebook, by building
on the specific results obtained in the cooperation with FACC. This guidebook will
then form the basis for the cooperation of
Airbus with any supplier in the Engineering segment. After all, the results obtained
within the scope of the Extended Enterprise
Program have demonstrated that in the aerospace industry cooperation holds promising potential for the future. Both partners will
benefit from the further standardization and
intensification of the collaboration between
OEM’s and suppliers.
FACC Engines & Nacelles
translating sleeves,
engine components
FACC Aerostructures
spoilers, winglets
FACC Interiors
door covers, smoke detector
panels, baggage compartments
pa ge 20–21
The Prize for Excellence
Excellent Supplier Award 2012
At FACC, total customer satisfaction is the paramount objective. Excellent suppliers play a vital role in allowing us to achieve
this aim. In order to publicly recognize their contributions and express our gratitude, FACC gives out annual supplier awards. In
addition, FACC also issues a Special Performance Award to acknowledge achievements that cannot be measured by conventional methods (product quality, delivery reliability, flexibility, customer service, ...). The award-winning companies for the year
2012 are:
Gold:
Paul Fabrications Ltd – AGC Aerospace & Defense/England.
The specialist for complex welded and machined assemblies.
Silber:
Stükerjürgen Aerospace GmbH & Co KG/Deutschland.
Competence in processing and development of thermoplastics.
Bronze: Cyclone Manufacturing Inc/Kanada.
The full-service provider for machining of structural components.
Special Performance Award:
Fill Ges.m.b.H./Österreich.
The leading company in the construction of machinery and special-purpose machinery.
Awardwinning
Minister Doris Bures, presenting the award to
FACC’s CEO Walter A. Stephan.
Ta k e off, Is s u e 2 /1 3
FACC becomes
first frontrunner
enterprise in
Austria
FACC AG is the first-ever enterprise to receive the new Frontrunner Award from the
hands of Doris Bures, the Austrian Minister for Innovation. Issued by the Federal
Ministry for Transport, Innovation and Technology, this prize is given to outstanding
innovative enterprises that are Europe-wide and world-wide technology and innovation
leaders in their market segments. The ceremonial presentation of the award took place
on May 15, on the occasion of the FACC Management Day, when FACC also handed
the first spoiler for the 787-9, the newest member of the Dreamliner family, to Boeing.
Flying without
wings
Fascinating Four Hills Tournament
Ski jumping enthusiasts from around the world know it. And everybody in Austria and Germany is familiar with it. Generations of children have grown up
with it. In our part of the world, Christmas holidays and live TV broadcasts of
the Four Hills Tournament belong together like New Year’s Eve and fireworks.
And in 2013/14, this tournament will again captivate huge audiences with its
four ski jumping events at Oberstdorf (Germany), Garmisch-Partenkirchen
(Germany), Innsbruck (Austria), and Bischofshofen (Austria).
Parallels to the aerospace industry.
In 5 seconds from 0 to 90 kph, 4 seconds of being airborne, with the heart rate at 180, and the
body subjected to forces similar to those acting on a jet pilot. Like in aeronautical engineering, the
continued optimization of aerodynamics and materials plays a vital role. Wind tunnel testing (some
say the ski jumpers used wind tunnels even before Formula 1), computer-based aerodynamics
calculations, and the constant upgrading and refinement of materials are key factors. The jumper is
the “aircraft”, his or her flying performance combines athletic and aesthetic prowess like almost no
other sports discipline (also the style scores count!). Similar to an aeroplane changing the angle of
attack and moving flaps and spoilers, the athlete optimizes his flight by making adaptations to his/
her posture.
Sports event and public celebration.
Bischofshofen is less than a two hours drive from FACC’s headquarters in Ried. On January 6, 2014,
it will also be the venue of the final round of the Four Hills Tournament that, year after year, attracts
thousands of spectactors. However, just like at the other locations of this tournament, which will kick
off on December 29, 2013, in Oberstdorf, Germany, only few visitors will bother to take in the beauty
of the surrounding alpine scenery. Rather, all Austrians will be hoping for a continuation of the success story of the Austrian team, perhaps even with Gregor Schlierenzauer, the winner of the last two
editions of this tournament. Yet, also spectators from Germany, Switzerland, Poland, Norway, the
Czech Republic, Slovenia, Finland, Japan, and from other nations will be vociferously cheering on
their athletes to claim the victory in this prestigious sports, tourism and society event that has taken
place every year since 1952 and never failed to score high on the goose pimple factor scale.
Panalpina
Logistics
Centre for
FACC.
FACC AG has, for many
years, worked together
with Panalpina, the globally active and leading
provider of freight and logistics services. Now, Panalpina is about to start
providing the supply logistics for FACC‘s plants in
the Ried region. For this
purpose, it will establish a
brand-new logistics centre
in the immediate vicinity of
FACC‘s plants in St. Martin. On premises covering
5,500 m², Panalpina will
bundle the goods receipt
and warehouse logistics
for FACC. It is from there that the components
needed for manufacturing
will be brought directly to
the production lines of the
various FACC plants. Over
30 employees will be in
charge of goods receipt,
customs clearance, quality
inspections, IT networks,
and distribution. It is the
first project of this kind
that Panalpina implements
for a customer and partner in Austria.
Maiden
Flight of
Bombardier
CSeries.
At Bombardier, things are
moving right on track. On
September 16, the CSeries successfully completed its maiden flight. For
this eco-friendly and fuelsaving family of regional
jets, FACC is supplying
15 m long fairing elements
made up of 73 composite
assemblies.
pa ge 22–23
facc
Interiors
Extend Your Expectations.
Comfortable & functional.
Aircraft manufacturers are constantly looking for low weight and durability, and
passengers equally demand comfort and an appealing design. In either case,
functionality is an essential and FACC Interiors delivers both in serial production for
commercial airliners and as customized parts for private jet aircraft.
From baggage compartments to lavatories, from the optimization of space to fascinating lighting concepts, from the comfortable feel of surfaces to an appealing
appearance – FACC’s solutions are convincing in every detail, setting the trends for
the future of civil aviation.
Pilot. Passion. Partnership.