FFT Group Your Turn-Key-Partner for Production Systems
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1 FFT Group Your Turn-Key-Partner for Production Systems Geschäftsanbahnung in der mexikansichen Luftfahrtindustrie für deutsche Zulieferunternehmen August 2013
2 FFT Group - Company Presentation FFT Turn-Key-Partner for Production Systems Introduction and Structure Aviation Experience Our Aviation Experience Fields of Activity Range of Services Research & Development New Technologies References of the FFT Group Aircraft References Page 2 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
3 ATON GmbH Dr. Lutz Helmig, shareholder Thomas Eichelmann (CEO) / Jörg Fahrenbach (CFO) Total turnover: approx. 2,23 billion euros and approx. 18,571 employees in 2012 AT Tech AT Tech AT Mining Tech AT Med Tech AT Aviation 100% EDAG GmbH & Co. KGaA Engineering Service Provider 100% dh mining system GmbH Special Coal Mines Machines 100% Haema AG Private Blood Donation Service 100% DC Aviation GmbH Business Jet Charter 100% FFT EDAG Produktionssysteme GmbH & Co. KG Plant Construction 100% J.S. Redpath Holdings Inc. Leading Global Specialist Mining Contractor 100% W.O.M. WORLD OF MEDICINE AG Medical Engineering 100% Augsburg Airways GmbH Regional Flight Company 100% REFORM Maschinenfabrik Machine / Plant Construction 100% Ziehm Imaging GmbH Medical Engineering 100% ATON Prisma GmbH Laser Technology 100% OrthoScan, Inc. Medical Engineering 90, 4 % RÜCKER AG Engineering Service Provider % TSO Industrieanlagen Planung und Vertrieb GmbH Machine and Plant Construction for bulk goods Page 3 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
4 FFT s Company Structure as part of the ATON Network Manfred Hahl (CEO) + Peter Walper (CFO) Jörg Ohlsen (CEO) + Rainer Bauer (CFO) FFT EDAG GmbH & Co. KG Production Systems Manfred Hahl Aviation Werner Lotz + Martin Neuland EDAG GmbH & Co. KGaA Product Development + Tools and Body Systems Jörg Ohlsen EDAG Production Solutions GmbH & Co.KG Rainer Wittich Locations: 3 National Holdings: EDUCATIONCENTER BBZ GmbH, Fulda FFT EDAG PS, Fulda Scherwo, Gauting National Location: FFT EDAG PS, Fulda Locations: 14 National Holdings: EDAG Rail GmbH, Fulda ELAN-AUSY (49%), Hamburg Locations: 12 National Holdings: EDAG PS, Hamburg International Holdings : International Location: International Holdings : International Holdings : FFT Spain, Valencia FFT Mexico, Puebla Pue. FFT Romania Campulung FFT EDAG USA, Detroit FFT EDAG China, Shanghai FFT EDAG China, Shanghai FFT EDAG Russia, Moscow EDAG Hungary, Györ EDAG Brasil, São Paulo EDAG USA, Detroit EDAG Japan, Yokohama EDAG England, Cranfield EDAG Malaysia, Kuala Lumpur ELAN-AUSY (49%), Toulouse ELAN-AUSY (49%), Madrid EDAG India, Neu Delhi EDAG Czech Rep., M. Boleslav Page 4
5 FFT EDAG Produktionssysteme GmbH & Co.KG Founded in 1974 FFT EDAG Produktionssysteme GmbH & Co.KG accept full responsibility for the production plants of tomorrow. Apart from handling the complete development of production plants in conjunction with our sister company EDAG GmbH & Co. KGaA, we offer turnkey services for the implementation of complete systems. We feel a particularly deep commitment to upholding standards in the process stability, flexibility and adaptability of production facilities. Global represence Sales (2012): 400 million Employees (2012): 1,610 Page 7 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
6 Integrated Development Turn-Key Assembly-Lines Turn-Key Body-in-White Lines Turn-Key-Engineering Digital Factory Our sister company as part of the ATOn network Page 8 Copyright 2011 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Vertraulichkeit, Horvath, Christoph (Marketing), 11/2011
7 Worldwide Wherever you need us Detroit Europe (33) Spartanburg Beijing Seoul Yokohama Shanghai New Delhi Puebla Pue. Pune Kuala Lumpur Walvis Bay São Paulo EDAG Product Development FFT EDAG Production Systems and Aviation EDAG Production Page 11 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
8 North America operations Locations Detroit Spartanburg Detroit (USA) Employees: 30 Engineering & Design Commissioning and integration of Complete line systems Puebla Puebla Pue. (Mexico) Employees: 210 Project and Technology Centre for the Mexican market Complete process chain for design and manufacturing of turn-key equipment Spartanburg (USA) Employees: 10 Project management Onsite Engineering & Design Support Page 12 Copyright 2011 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Vertraulichkeit, Horvath, Christoph (Marketing), 11/2011
9 Resources FFT NAO Mechanical and Controls Engineering Manufacturing & Certification Facilities (floor area) CAD-System FFT Detroit FFT Mexico A-CAD / mech. Desktop CATIA V4 CATIA V5 Unigraphics Micro Station V8 Process Simulate / Rob CAD Delmia E-Plan P8 Simulate S Built centre Puebla CNC-machines NC-machines large drill press small drill press milling machine grinder lathe Stiefelmeyer CMM mobile Theodolite Cert. System mobile FARO Cert. System Laser certification System Assembly area FFT Detroit Area total 6000m Assembling area FFT Mexico mechanical 7400m electrical 600m Area total 8000m Page 13 Copyright 2011 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Vertraulichkeit, Horvath, Christoph (Marketing), 11/2011
10 FFT Group - Company Presentation FFT Turn-Key-Partner for Production Systems Introduction and Structure Aviation Experience Our Aviation Experience Fields of Activity Range of Services Research & Development New Technologies References of the FFT Group Aircraft References Page 14 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
11 Aviation Experience ELAN & EDAG Structure & Cabin Design, Mock-Up, Planning A320 Moving Line A380 CFRP A380 Sec.18/19 A380 Sec.Opt. A380 Mock-Up A380 Tail Bump. A400M Sec. Bracket Design A350 Flex Mock-Up EDAG as PCC & DEAS Jigs & Tools A320 FAL China Tianjin A330 Joining Sec. 13/14 A320 Rudder China Harbin A350 Wing Equipping FFT EDAG Testing & Automation Systems A350 FTTB A350 RJD & VTP Wind Tunnel A350 Stringer Pos. THSA A350 HTP A350 Barrel 1 Page 15 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
12 FFT Group - Company Presentation FFT Turn-Key-Partner for Production Systems Introduction and Structure Aviation Experience Our Aviation Experience Fields of Activity Range of Services Research & Development New Technologies References of the FFT Group Aircraft References Page 16 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
13 Aerospace - Aircraft Automation Systems Automation Systems: Process Planning Simulation Positioning Technology Application Systems Robot Automation controlled by external Measurement Systems Page 17 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
14 Aerospace - Aircraft Testing Systems Testing and Quality Assurance: Development of Technical Test Specifications Leakage Test Wiring Test Hydraulic Systems Test Structural Test Iron Bird Test Equipment for Hydraulic Cylinder Page 18 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
15 Aerospace - Aircraft Equipping Systems Equipping Systems: Logistics Planning Planning and Realisation of the Equipping Station Pre- & Final Equipping Transportation Devices Handling Devices (Lift & Hoisting Devices) Assembly Devices (Jigs) Drilling Templates Page 19 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
16 Aerospace - Carbon Fibre Manufacturing Systems Carbon Fibre Manufacturing Systems: Roller-Heating-Unit for Positioning of Stringer Application Technologie for Fixing and Form-Cutting of Tapes Application Technologie for Fixing and Positioning of Filling Material Special Endeffector Technologie for Positioning of Carbon Fibre Material Page 20 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
17 Fields of Activity of the FFT Production Systems GmbH Quality Management Service From product development to SOP and after sales» Quality planning APQP» Quality control Feasibility study» Quality assurance Plan - Do - Check - Act» Quality improvement CIP, Kaizen Product Compliance and Documentation Service targets» Creation of target group-oriented communication media» Application of service & guarantee strategies» Long-term integration of "best practices" in product creation process References References Aerospace Rail Automotive Automotive Aerospace Automotive Supplier management First article inspection - FAI Special quality tasks FMEA execution Value stream mapping Quality support Automotive Automotive Aerospace Aerospace Mechanical engineering Automotive Automotive After-sales literature Repair advice/support Manuals: S1000D, ispec2200 CE documentation Product descriptions Online portals, specifications Learning media, illustrations Page 21 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
18 FFT Group - Company Presentation FFT Turn-Key-Partner for Production Systems Introduction and Structure Aviation Experience Our Aviation Experience Fields of Activity Range of Services Research & Development New Technologies References of the FFT Group Aircraft References Page 22 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
19 Aerospace Research & Development in the Field of Carbon Fibre Total Line Control Systems EVo (DLR-ZLP-Stade) Development of Gripper- and Handling Systems for High Positioning Control Center HMI Management Steering Integration of Fill Material Detailed Planning Series Production Simulation Roll- / Adhesive Endeffector Integration of an external Measurement System Stringer Preparation & Adhesive Application / Cutting Concept Design: Flexible Forming Gripper Page 23 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
20 Aerospace Automatical Edge Sealing of Carbon Components Example: Automatical Edge Sealing Station for CF-Clips Resin Application Process Feeding Process Curing Process Edge Preparation Process by suction blasting FFT Interface to AB.RO.POS SPS Control Page 24 Copyright 2011 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Vertraulichkeit, Horvath, Christoph (Marketing), 11/2011
21 Aerospace Current Research Project s ( ) Airbus Stade Flexmont - Flexible one-step installation of closed CFK box structures (VTP) in commercial aircraft o o o o Flexible system concept adapting the system to possible component derivates Implementation easier and more accessible facility structures Minimize Shim operations through a new concept of tolerance High degree of automation through innovative automation concepts Premium Aerotec Nordenham EfF-CFK+ - Effective technique for CFK prepreg components + innovation for a simplified process chain o o o Development of new processes for end-effectors and the forming of complex aircraft components considering the high quality requirements Integration of a flexible positioning to minimize the costs in case of changes and adjustments Development of a suitable surface treatment to the chain of automatic preparation Page 25 Copyright 2011 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Vertraulichkeit, Horvath, Christoph (Marketing), 11/2011
22 FFT Group - Company Presentation FFT Turn-Key-Partner for Production Systems Introduction and Structure Aviation Experience Our Aviation Experience Fields of Activity Range of Services Research & Development New Technologies References of the FFT Group Aircraft References Page 26 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
23 Aircraft References in Detail Wing Equipping Objective A350 XWB Wing Equipping Tooling park for AIRBUS Bremen and Broughton Scope of Supply Planning, Design, Manufacturing & Commissioning Tooling's for the complete Wing Equipping Assembly Jigs, Handling Systems, Installation Tooling's, Hoisting Devices, Transport Frames & Carriages, Dummies, Gauges, Safety Devices Schedule Page 29 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
24 Aircraft References in Detail Root Joint Demonstrator & VTP Full Scale Test Rig Objective Development and Manufacturing of a complex Full Scale Test Rig to test the Joining between Section 19 and VTP Scope of Supply Development and Static Calculation Manufacturing of the Test Rig Positioning and Orientation of the Hydraulic Actuators Dimensions LxBxH 15m x 9m x 9m Schedule 2010/2012 Page 30 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
25 Aircraft References in Detail Flight Test Tailbumper System Objective Development and Implementation of a Flight Test Tailbumper System into the Section 18 Scope of Supply Development and Calculation of the System Manufacturing of the System Development, Calculation and Manufacturing of a Test Facility to test the Hydraulic Tailbumper Cylinder max. Test Pressure: 570 bar max. Piston Speed: 1,29 m/s Schedule 2010/2012 F= 880 kn Page 31 Page 31 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
26 Aircraft References in Detail VTP & HTP Assembly Objective Legacy 450/500 Jigs for the Vertical and Horizontal Tailplain Assembly for EMBRAER Portugal Scope of Supply Design and Manufacturing, Assembly & Commissioning Assembly fixtures for VTP & HTP production Drilling Templates CFRP and Aluminum Transportation Carriages, Hoisting Devices Schedule 2011/2012 Page 32 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
27 Aircraft References in Detail Stringer Positioning on Shell Absolute Robot Positioning Objective Implementation of Automatic Stringer Positioning on Shell Tolerance +/- 0,2mm by 18m length Advantages Stringer Position according to CAD data Force Control during the assembly process Robotic s on Driving Axle with Roll-/Adhesive Endeffector Self Referencing - High Precision Technology Schedule 2010/2012 Page 33 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
28 Aircraft References in Detail Rudder for Harbin, China Objective A320 Rudder Assembly Tooling for AIRBUS Harbin, China Scope of Supply Design and Manufacturing, Assembly & Commissioning in China Assembly fixtures for the Rudder production Drilling templates, Transport Carriages Schedule Page 35 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
29 Aircraft References in Detail Fuselage Positioning System Objective Implementation of Assembling Section Scope of Supply Implementation of lot 630 Positioning of Section 13 Positioning of Section 14 Assembling of the Sections Implementation of lot 631 Schedule Positioning of joint 13/14 Rework and Measurement Station Page 36 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
30 Aircraft References in Detail Final Assembly Line Objective Implementation of the complete A320 FAL in Tianjin (China) with local content Scope of Supply Dürr EDAG is the only supplier world wide, who realized this kind of project in China Invest approx. USD 100 Million More than 12,000 tools > 1,000 tons steelworks (platforms etc.) Engineering in China Global resources with locally available capabilities (from design to commissioning and service) All customer milestones met Schedule Page 37 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
31 Aircraft References in Detail Fuselage Assembly Station Objective High level fuselage alignment system for section 18/19 Achieve assembly tolerances of 0.3 to 0.5 mm Scope of Supply fuselage assembly concept Design of laser guided fuselage positioning system FEM Simulation Implementation Ramp up support Schedule fuselage assembly implementation Page 38 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
32 FFT Group - Company Presentation Thank you for your attention FFT EDAG Produktionssysteme GmbH & Co.KG Reesbergstrasse Fulda
33 Customer References Wide Spread Aircraft Experience in Assembly, Equipping and Testing 2013 Airbus Operation, Plant Toulouse (F) A350 Transportation Jigs fot HTP Movable Parts, S11-14 & S13-14 EQ, S13-14 STR and S16-18 Side Shells 2012 Premium Aerotec, Plant Nordenham (D) Stringer Integration on a A350 Barrel in our Multifunction Robot Station 2012 Airbus Operation, Plant Hamburg (D) A350 HTP Dummy and S19 Access Platform, Planning and Realization Page 41 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
34 Customer References Wide Spread Aircraft Experience in Assembly, Equipping and Testing 2012 Embraer VTP/HTP, Portugal Legacy 450/500 Jigs for the Vertical and Horizontal Tailplain Assembly 2012 Comac/SAMC Plant Shanghai (China) C919 Moving Final Equipping Line, with Testing and Internal Logistic 2011 DLR, Plant Stade (D) ZLP Evo Pak.6 Master Control System for mass production of Carbon Fiber Products 2011 IRKUT, Plant Irkutsk (RUS) MS-21 Final Assembly Line for Equipping, Planning and Realization 2011 Airbus Tianjin, Plant Tianjin (China) Development and Production of 7 standardized Grinding Tables with extra low pollution and noise impact solution 2011 Comac/SAMC, Plant Shanghai (China) C919 SE-Planning-Phase of Moving Final Assembly Line, Equipping, Testing and Internal Logistic 2011 IRKUT, Plant Irkutsk (RUS) MS-21 Concept Planning Assembly, Testing and Internal Logistic Page 42 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
35 Customer References Wide Spread Aircraft Experience in Assembly, Equipping and Testing 2010 Airbus Operation, Plant Bremen (D) Modifikation THSA (Trimmable Horizontal Stabilizer Aktuator) Test Rig 2010 Airbus Operation, Plant Bremen (D) Wind Tunnel Seeding Device integration 2010 Premium Aerotec, Plant Nordenham (D) Stringer Robotic Positioning on Shell 2010 Airbus Operation, Plant Harbin (CHN) A320 Rudder Tooling for Harbin 2010 Airbus Operation, Plant Bremen (D) & Broughton (GB) A350 Wing Equipping Final Assembly Line 2010 Airbus Operation, Plant Hamburg (D) A350 Root Joint Demonstrator & VTP Full Scale Test Rig 2010 Airbus Operation, Plant Bremen (D) A350 Flight Test Tailbumper System 2010 Embraer VTP/HTP, Brazil and Portugal Legacy 450/500 System for Vertical and Horizontal Tailplain Assembly Page 43 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
36 Customer References Wide Spread Aircraft Experience in Assembly, Equipping and Testing 2008 Airbus Deutschland GmbH, Plant Finkenwerder (D) Delivery and Installation of the fuselage positioning system for A330F, lot 630 & Airbus Deutschland GmbH, TJFTZ (CHN) FAL China Long Lead Items for the Final Assembly Line A320 in Tianjin, China, Delivery and Installation of 16 Fuselage positioning supports and 2 wing positioning systems incl. electrical control 2005 Airbus Deutschland GmbH, Plant Finkenwerder (D) Manufacturing of the A380 Mock Up for the Interior Expo Airbus Deutschland GmbH, Plant Finkenwerder (D) Development Moving Line equipment installation SA + LR 2004 Airbus Deutschland GmbH, Plant Finkenwerder (D) High level fuselage alignment system for A380 Section 18/ Airbus Deutschlang GmbH, Plant Stade (D) Assembly System for A380 Vertical Tail Plane. Vertical tail height: 14 m, weight 3.5 tons Page 44 Copyright 2012 FFT EDAG Produktionssysteme GmbH & Co. KG. All rights reserved. Heinz Koellgen (Sales), 11/2012
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