The FACC Information Magazine Issue Creating Future. page 4-5. Next Generation Engines. page Engineering Excellence.

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1 The FACC Information Magazine Issue 2 13 Creating Future page 4-5 Next Generation Engines page Engineering Excellence page 21

2 contents 4 5 Creating Future FACC s Technology Center and Test Center 6 7 FACC Open 5 Inauguration of FACC s Technology Center and Test Center 8 9 Spoilers and ailerons for E-Jets E2 First Aerostructures contract awarded by Embraer Production with new Technologies FACC delivers flaps for Airbus A Split and save big! FACC makes split scimitar winglets for Boeing 737NG 13 Design optimized! Translating sleeves for Boeing Powerful Nacelle Components & Bypass Ducts Insider Continued Partnership & Best for West Next generation Engines FACC develops new annulus fillers in a collaborative effort 20 Best Practice as a Win-Win Situation FACC project to optimise assembly line for luggage compartments 21 The formula for Engineering Excellence FACC as a partner in an Airbus pilot project 21 A350 completed maiden flight Each of FACC s three divisions was on board 22 The Prize for Excellence Excellent Supplier Award Award-winning! FACC becomes first frontrunner enterprise in Austria 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. Take off, Issue 2/13

3 An autumn of soaring to new heights! editorial 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 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 , 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 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 5000 th pair of winglets. This makes FACC the global leader for these fuel saving components. 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. 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, Walter A. Stephan CEO of FACC AG page 2 3

4 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. Take off, Issue 2/13

5 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. page 4 5

6 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. 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 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 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. Take off, Issue 2/13

7 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. Saralaya Prakash & Lingasheddar Nanjundesh, TAAL Events/Opening-of-the-new-FACC- Technology-Center 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. page 6 7

8 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. E-Jets E2 Evolutionary lead Embraer announced the launch of its new commercial aircraft program at the Paris Airshow mid June 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. 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 Q to support aircraft entry service in E-JEts maintena Take off, Issue 2/13

9 ns 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) Lighter Quieter nce-friendlier page 8 9

10 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. Take off, Issue 2/13

11 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 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. page 10 11

12 THE BOEING is the first model of Boeing s Dreamliner family. This super-efficient 56 m (184 ft) long jet airliner seats up to 250 passengers. With total orders for the at 498 planes, it is currently the most popular of Dreamliner models. FACC supplies spoilers, lower bonded panels, horizontal stabilizer forward box and trailing edge panels, translating sleeves, and engine components. THe Boeing is the second member of the super-efficient Dreamliner family, stretched by 6 m (20 ft). This provides the necessary extra space tal stabilizer forward box and trailing edge panels, translating sleeves, and engine components. The Boeing is the third and longest member of the 787 family. Extra length added to its fuselage makes this model 68 m (223 ft) long and increases its seating capacity to more TRANSLATING SLEEVES. Reverse 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 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 Checklist to seat up to 290 passengers. Its successful first flight took place on September 17, FACC supplies spoilers, lower bonded panels, horizon- Scalloped Chevron. The new design includes chevrons as were introduced on the previous model. than 300 passengers. Again, FACC components will be part of the package. Take off, Issue 2/13 thrust is a method to assist jet aircraft in slowing down upon touchdown. The engine s exhaust air is diverted in a forward direction by extendable flaps/doors. FACC is a specialist for the sleeves including the thrust-reverser doors and the connection elements.

13 Design optimized! Translating sleeves for Boeing 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 In 2010, this contract was extended to also encompass the new 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 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 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. page 12 13

14 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. 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. PerfoRMANCE Team Spirit output Respect Strong Team Effort. 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. A team for customers to count on: FACC s project team at the initial customer delivery Take off, Issue 2/13

15 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. Strong, quiet, and aerodynamically optimized. The bypass ducts developed by Pratt & 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 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. 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. page 14 15

16 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 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. Take off, Issue 2/13

17 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. Pininfarina, a company based in Northern 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. Staff from FACC partnered with Alenia during the development efforts at their site in Naples. Then, FACC completed the entire industrialization including toolmaking within less than 5 months. Meanwhile, the first cabins have already been installed. The place of installation is at Superjet International in Venice. Since September 18, two SSJ100 of the Mexican airline Interjet have been operational in commercial service. 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 saves weight. The toilet wall with two directly mounted seats for flight attendants is made of carbon, instead of the standard aluminium. And, FACC not only supplies the complete cabin panelling, but also the cargo compartment lining. The latter for all SSJ100 jets Eastern and Western versions. page 16 17

18 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. Take off, Issue 2/13

19 Composites save weight. 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. Excellent result. 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 The patent for part and production method is pending. Annulus Filler: FACC innovation for greener engines page 18 19

20 Training Shopfloor Quality at work 1 Analysis Transparency 2 Optimization Logistics 3 Best practice 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 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 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. Take off, Issue 2/13

21 1+1=1 The formula for Engineering Excellence FACC as a partner in an Airbus pilot project The A 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 A 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. 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. 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. FACC Engines & Nacelles translating sleeves, engine components FACC Aerostructures spoilers, winglets FACC Interiors door covers, smoke detector panels, baggage compartments page 20 21

22 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 FACC becomes first frontrunner enterprise in Austria Minister Doris Bures, presenting the award to FACC s CEO Walter A. Stephan. 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. Take off, Issue 2/13

23 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. page 22 23

24 faccinteriors 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.