afs introduction

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Introduction to Alcoa Corporation, Alcoa Fastening Systems and update on fastener regulations Presentation to Embraer May 12, 2004 Luke Haylock Director of New Product Development

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Page 1: AFS Introduction

Introduction to Alcoa Corporation, Alcoa Fastening Systems and update on fastener regulations

Presentation to Embraer May 12, 2004

Luke Haylock

Director of New Product Development

Page 2: AFS Introduction

Alcoa OverviewAlcoa Overview

• Founded in 1888• 127,000 employees• 350 operating locations in 38 countries• Over $20 billion in annual revenues

Alcoa Today

• To be the best company in the world• Best Employer• Best Supplier• Best Neighbor• Best Investment

Alcoa’s Vision

Page 3: AFS Introduction

How we do businessHow we do business

Three Strategies one underlying principle:

• Make to use• Defect free• At lowest cost• Safely

New “ideal”1. Diverse business platforms in market and technology leadership position

2. Operating excellence and continuous elimination of waste

3. People linchpin the system

Page 4: AFS Introduction

Environmental, Health and SafetyEnvironmental, Health and Safety

• Alcoa is one of the safest companies in the world…if not the safest

• Safety is one way we show our employees how much we value them

• 45% of facilities worldwide have operated without a lost workdayinjury since 2003

Page 5: AFS Introduction

Alumina & Aluminum24.6%

Alumina & Aluminum24.6%

Building & Construction

10.8%

Building & Construction

10.8%

Industrial Products, IGT, Distribution,

Other14.8%

Industrial Products, IGT, Distribution,

Other14.8%

Aero, Auto, Commercial

Transportation25.1%

Aero, Auto, Commercial

Transportation25.1%

Packaging24.7%

Packaging24.7%

Alcoa’s Market PresenceAlcoa’s Market Presence

$20.3 Billion in Revenues$20.3 Billion in Revenues

2002 Revenue by Market

Page 6: AFS Introduction

Alcoa’s Product and Process Technology in Today’s AircraftAlcoa’s Product and Process Technology in Today’s Aircraft

Page 7: AFS Introduction

Alcoa Fastening Systems Alcoa Fastening Systems Our HistoryOur History

• 2000 - Huck Fasteners and Howmet join Alcoa in the acquisition of Cordant Technologies

• 2002 - Alcoa acquires Fairchild Fasteners from its former parent company, (Fairchild Corporation), and develops a new Business Unit called:

• Alcoa Fastening Systems is an integration of (at least) 3 Companies, not just 2

Alcoa

Huck

Fairchild

Page 8: AFS Introduction

Aerospace and Commercial Transportation StructureAerospace and Commercial Transportation StructureMarket Sector ChangeMarket Sector Change

$130

$180

$565

Sheet &Plate

Extrusions

Forgings

•$180•$130

•$1,000

•$800

•$565

• Howmet• Fasteners• Sheet / Plate• Extrusions• Forgings

TodayBefore 2000

Page 9: AFS Introduction

Alcoa Fastening Systems At a GlanceAlcoa Fastening Systems At a Glance

HeadquartersTorrance, California USA

Key MarketsAerospace and Commercial

Employees5,500 worldwide

Primary ProductsFastening Systems, Machined Components Installation Tool Systems

Revenue (2002 combined)Approx. $800 Million US

Manufacturing Facilities26 locations7 countries

Page 10: AFS Introduction

AFS Worldwide Current…AFS Worldwide Current…

VougyVougy

MarignierMarignier

KelkheimKelkheim

SaintSaint--CosmeCosme

NemesvamosNemesvamosMontbrisonMontbrison

ToulouseToulouse

TelfordTelford

HildesheimHildesheim

KingstonKingstonWacoWaco

TorranceTorrance

CarsonCarson

Fullerton Fullerton

COICOITucsonTucson

StoughtonStoughton

OakleighOakleigh

MelbourneMelbourne

UsUs

SimiSimi

BardonBardon

AichachAichach

Cergy/UsCergy/Us

Page 11: AFS Introduction

AFS Business ObjectivesAFS Business Objectives

•• Zero accidentsZero accidents

•• 100% environmental compliance100% environmental compliance

•• BestBest--inin--class fastening solutions providerclass fastening solutions provider

•• 100% On100% On--time Deliverytime Delivery

•• Zero DefectsZero Defects

•• Best leadBest lead--timestimes

AFS Destination Statement:AFS Destination Statement:

To be recognized as the global industry leader in environment, health and safety, on-time delivery, customer service and technical support, cost-effective supply of fasteners, components, fastening systems, and logistic solutions with zero defects; to lead the industry in innovation in Design and Development, and product breadth.

Specifically:Specifically:

Page 12: AFS Introduction

Aerospace Product FamiliesAerospace Product Families

• Blind Fasteners (Bolts & Rivets)• Bolts & Recess Fasteners• Fluid Products• Inserts & Studs• Latching Systems & Related Mechanisms• Lockbolts (Pins & Collars)• Nuts• Panel Fasteners• Pin Systems (Pins, Collars & Nuts)• Assembly Tool Systems

Page 13: AFS Introduction

Brand NamesBrand Names

• Camloc ™• Delron ™• Eagle ™• Huck ™• Kaynar ™• K-Fast ™• Mairoll ™• Mecaero ™

• Microdot ™• RAM ™• Rosan ™• Screwcorp ™• Simmonds ™• SNEP ™• Tridair ™• Voi-Shan ™

+ Assembly Tool Systems (ATS) ™

Page 14: AFS Introduction

Logistics SystemsLogistics Systems

Simple Kits Repair Containers

VendFast®Available in various Configurations

Dassault Fixture KitsTrolley Cart & Tray System

Page 15: AFS Introduction

Quality Assurance ExcellenceQuality Assurance Excellence

Worldwide CertificationsISO-9000-2000 Quality Management Systems

EN-9100-A Aerospace Quality Design, Development, Production, Installation & Servicing

AS-9100-A Aerospace Quality Design, Development, Production, Installation & Servicing

TS-16949 Quality Systems - Automotive Supplies

QS-9000 Quality Management System for Automotive Suppliers

NADCAP National Aerospace & Defense Contractors Accreditation Program

FAR-21-303 Federal Aviation Administration

FAA-ODARS Certification North American Operations & Logistics Centers

JAR 21.303 Joint Aviation Authority

Operating worldwide under a single Global Quality Assurance System

Page 16: AFS Introduction

Customer Support StrategyCustomer Support Strategy

•• Worldwide ManufacturingWorldwide Manufacturing

•• Worldwide Customer SupportWorldwide Customer Support

•• Worldwide Technical SupportWorldwide Technical Support

•• Worldwide New Product DevelopmentWorldwide New Product Development

•• Worldwide Distribution / LogisticsWorldwide Distribution / Logistics

Page 17: AFS Introduction

New Product Development StrategyNew Product Development Strategy

• We develop new products in response to customer’s needs – Search for opportunities to reduce weight

– Increase assembly efficiency

– Facilitate development of efficient airframe structures

• Our main Aerospace NPD Center is located in Carson, California

• Second NPD center will be located in Toulouse, France

• Focus on projects with significant long term growth potential

• Close working relationship with Alcoa Technical Center

• Regular Technical Symposiums with Customers

Page 18: AFS Introduction

Olivier JarraultPresident AFS

Martin RyanSr. VP Technology

AFS Worldwide

Don BusbyPresident AFSCommercial

Claude LuratiPresident AFS

Aerospace Europe

Luke HaylockNPD Director

AFS Aero Worldwide

Louis ValisEngineering Manager

Waco

Genevieve LacombeManager NPD

European Operations

OpenSr. Engineer

Hai-Tao WangManager NPD Center

Gerry HufnaglSr. Principal

Engineer

Liang ZengSr. Engineer

Frank CosenzaConsultant

Al YamamotoConsultant Christian Pouplier

EngineeringManager

St. CosmeOps.

Dieter JulingEngineering

ManagerKelkheim Ops.

Andreas ZenkeEngineering

ManagerHildesheim Ops.

Tom HarbinSr. Engineer

Ernie MonserrattR&D Test Engineer

Oviedo ArcienegaR& D machinist

Van DangR&D Machinist

Terry VanceR&D machinist

Frank WlaterR&D Technician

Jim EllwoodR&D Test

Technician

M. CarmenAmezquitaR&D Testtechnician

NPD OrganizationNPD Organization

Page 19: AFS Introduction

NPD StrategyNPD Strategy

• Focus on our core competencies of specialty mechanical fastening systems.

• All projects must have high customer value

– Technical capability,

– Low life cycle cost

• Design for product and process safety (minimize liability)

• Promote proprietary products

• Maintain balanced portfolio approach

Page 20: AFS Introduction

•Current areas of focus

•Assembly automation•Assembly automation

High performance fastenersHigh performance fastenersFastener intensive subassemblies

Fastener intensive subassemblies

Page 21: AFS Introduction

Overview of FAA Fastener RegulationsOverview of FAA Fastener Regulations

Page 22: AFS Introduction

Regulatory Oversight Regulatory Oversight Standard PartsStandard Parts

Standard parts• A standard part conforms to an established industry or U.S.

government published specification.

– The FAA does not certificate manufacturers of standard parts. However, when a type design calls for the installation of a standard part, the FAA may conduct surveillance of the manufacturer and/or supplier of that part.

Page 23: AFS Introduction

Regulatory Oversight nonRegulatory Oversight non--Standard PartsStandard Parts

• Many specialized fasteners are manufactured to specifications that are known only to the manufacturer. Obtaining a Parts Manufacturing Approval for these specialized groups of fasteners, is not practical.

– To provide approvals under which these groups of parts could be produced, the FAA issued Technical Standard Order (TSO): TSO-C148, Aircraft Fasteners;

– TSO’s are not issued for standard parts nor for parts used in critical applications. In contrast to "standard part" nuts, bolts, etc., these fasteners, bearings, and seals must meet the TSO minimum performance, marking and installation approval requirements.

– Eleven companies currently hold authorization for TSO-C148

Page 24: AFS Introduction

Procurement ConsiderationsProcurement Considerations

• When purchasing and installing standard parts, consider the following:

– A Certificate of Conformity (C of C) should be provided by the producer of a standard part.

– A standard part should carry a mark indicating the part has been produced in accordance with the specification requirements.

– A part is no longer considered "standard" if it is used in a critical application that imposes qualification or quality control requirements beyond the standard specification.

– To facilitate traceability, commingling like fasteners from different lots is not recommended.