HITCO Carbon Composites_ Inc

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					HITCO Carbon Composites, Inc.
  Commercial Aviation, Defense and
     Aerospace Applications –
   Observations and Thoughts On
        Staying In Business
       Dr. Leslie Jay Cohen
AIRTECH 2008 – International Aerospace Supply
                     Fair
            November 11-13, 2008
  Exhibition Center Frankfurt/Main, Germany
Aircraft Structures
Glossary of Terms
     •   Pi    C t    t [Original Equipment M
         Prime Contractor [O i i l E i          f t
                                          t Manufacturer (OEM)]
          – Responsible for entire aircraft. Also known as Original Equipment
            Manufacturer (OEM).
          – Examples include: Boeing, Airbus, NGC, LMCO, Bombardier and Embraer
     •   Tier S   li
         Ti I Supplier
          – Responsible for design / delivery to OEM of major systems / sections, e.g
            wing and wing box
          – Investment partners with Prime Contractors on new programs.
     •   Tier S    li
         Ti II Supplier
          – Responsible contractually to Tier I firm for components / subsections (e.g. tail
            cone, floor beams, doors)
          – Roles expanded to include Design / Build responsibilities.
     •   Tier III Supplier
          – Builds parts in accordance with Materials, Design & Processes specified by
            Prime Contractor or Tier I, so called “Build to Print”.
     •             pp
         Tier IV Supplier
          – - Commodity supplier, e.g. prepreg, metals etc.
          “In a major departure from traditional airplane manufacturing, the Boeing 787
          Dreamliner is being mostly fabricated by a network of partners/suppliers, with major
          components then delivered to Boeing for final assembly…”
Aircraft Structures

                            Contents

                Trends
                Strategic Overview
                Growth Strategies
                      Automate, Consolidate-
                      Emigrate or Evaporate
                Summary
Boeing 787 Dreamliner Marks A Paradigm Shift in
Commercial Aircraft
   Composites are a key discriminator
     -   50% by weight carbon fiber reinforced composites.




   Moving from Work-Sharing contracts to Long Term Strategic Agreements with Tier
   I companies that Design and Build (Production carve outs).
   Most successful new airplane launch in Commercial Aviation History
     -   Firm orders of 567 aircraft from 44 customers; roll out 8 July 2007.

 “The clear objective is for Airbus to copy Boeing… become a systems integrator …
outsourcing as much structural work as possible to partners”

                                                                Richard Aboulafia / Teal Group May 2007
Aircraft Structures
Trends: Hand Lay-up Projections


 Composite Aircraft Structures Worldwide Market Size
Exceeding $4Billion / year with Less than 20% Projected
                to Utilize Hand Lay-Up.

 • Domestic companies that remain Tier III
 hand lay up factories will not survive in
 the future.
 • Majority of Hand Lay Up Fabrication will
 Migrate to Low Cost Countries over time.

                EMIGRATE !
A PICTURES MEANING CAN EXPRESS TEN THOUSAND WORDS




                WHERE ARE THE PEOPLE ?
Trends: Industry Consolidation
During past decade, several prime contractors have either been
  acquired or converted to subcontractor status:
   •   McDonnell Douglas acquired by Boeing
   •   Fokker shut down; became Stork
   •   General Dynamics (military aircraft) merged with Lockheed.
   •   Establishment of EADS
   •   Latecoere shuts down aircraft production




        Latecoere             Douglas                  Fokker

 Those firms which fail to adapt are either acquired, no
               o ge O s, o
              longer OEMs, or deceased
Compliments of Aero Strategy Marketing Consultants
 AUTOMATE – EMIGRATE OR EVAPORATE




      Volume
         rate
                 Automated Tape Laying
       15kg/h
                         (ATL)


                                     ATL constrained by a high degree
                                           of double-curvature
       10kg/h
                                                             AFP constrained by
        8kg/h                                                sub-component size

                                            Automated Fiber Placement
       5.5kg/h                                       (AFP)
         5kg/h                                                               4.7kg/h
         4kg/h
         3kg/h
                              Hand Lay-up         1.6kg/h
         2kg/h                                                                2kg/h
         1kg/h                                                    constrained by
       0.5kg/h                                                      mould size
                     Low            Medium            High        Very High
                                  Complexity of Mould Geometry and Lay-up

Boeing's Frederickson, WA plant:

ATL machine lays down plies of Toray Unidirectional tape
to build up skin of first B 787 tail fin                                               Thanks to SAMPE 2003 Keynote, Jens Hinrichsen & Chris Reed
                           HITCO Clean Rooms




BLDG. 1       7,100 ft.²

BLDG. 2      27,000 ft.²

BLDG. 3      36,000 ft.²
               ,

BLDG. 7       4,800 ft.²

BLDG. 13      6,900 ft.²

BLDG. 15      8,000 ft.²

BLDG. 73N     5,400 ft.²

BLDG. 73S     6,300

TOTAL       101,500 ft.²
                         Automated Tape Lay-up (ATL) Machines
                                Operational: March 2008 & April 2009
• Cincinnati Charger ATL 3”, 6” or 12” wide tape

    Patented segmented compaction show

    Layup on tool surface or honeycomb core

    Superior end placement via surface tracking



    1st unit operational, March 2008

          •30’ X 17’ X 4’ working envelope



    2nd unit operational, 1st Quarter 2009

          •43 17 4
          •43’ X 17’ X 4’ working envelope

  • ATL Machine / Ultrasonic Knife / CCA

    Room are approved to Boeing BAC5578

    and D6-55902 Type 1, Class 1.
            Automated Fiber Placement (AFP)


                  Operational Feb 2009




Cincinnati Viper 6000 Configuration will provide a Two Line Capability:

     • Tows, 1/8” or 1/4” wide material

     • Dual Mandrel Station mode: Ability to wrap two 16’ diameters x 29’ length

     • Single Mandrel Station mode: Ability to wrap 16’ diameter x 50’ length
AFP Facility




Bldg. 3 & 4 Replaced with
                     Ft.
New High Bay 40,000 Ft.²
This Building Increases Clean Room Capacity to 101,000 Ft.²
         Largest of three new Autoclaves




20’ x 50’ Autoclave Under Construction, Operational 1st Qtr 2009

         This will give HITCO a total of 12 autoclaves
The Big Picture



                             “If the world's best engineers are
                             produced in India or Singapore, that
                             is where our companies will go. This
                             is the reality in the modern world.
                             We locate facilities where we can
                             find or import talent.”
                                     — Craig Barrett, former CEO Intel, Times of
                                       India (03.07.2005)




 Source: Len Proveromo via Diana Hicks
HITCO WILL INVEST PERFORM AND GROW – AND EDUCATE OUR PEOPLE
ED CARSON COO HITCO – AVIATION WEEK AUGUST 20, 2007

      Large Autoclave (50’ X 45’)




                                         AFP 4RD Q 08




                                          ATL 3RD Q 08
           Facility U  d
           F ilit Upgrades

				
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posted:7/23/2011
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