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November 2006
Embraer
Industrial Architecture
Product portfolio
EMBRAER 170
ERJ 145 Series
EMBRAER 170/190 Series
ERJ 135 ERJ 140 ERJ 145 XR ERJ 145
AEW
EMBRAER 175 EMBRAER 190 EMBRAER 195
ALX Legacy Phenom
Defense Executive
Lineage
‘70s ‘90s ‘00s‘80s
Product Evolution
BANDEIRANTE(EMB 110/111)
TUCANO(EMB 312)
BRASILIA(EMB 120)
ERJ 145
EMB 145 AEW&C
ERJ 135
EMB 326
EMB 321
EMB 121
AMX
BRASILIA(EMB 120)
ALX(EMB 314)
LEGACY 600
ERJ 135
ERJ 140
EMBRAER 195
EMB 145 AEW&C SUPER TUCANO
AMX
ERJ 145
EMBRAER 170EMBRAER 175
EMBRAER 190
ERJ 145 XR
PHENOM 100PHENOM 300
P-99EMB 145 RS/AGS
AMXEMB 145 RS/AGS
ERJ 140
LINEAGE 1000
Industrial Operations
Parts
Parts
Fabric
ation
Fabric
ation
Machining TubingHarness Sheet Metal Composite
Sub-assembly Segments
Structu
ral
Structu
ral
Assem
bly
Assem
bly
Fuselage
Supplier
Supplier
EquipmentRaw Material Segments
System Installation and Tests
FinalFinal
Assem
bly
Assem
bly
Flight Preparation
DEL
IVER
Y
Painting
Manufacturing Processes
Embraer Units
Brazil
Brazil
Unit – Gaviao Peixoto
Unit – Eugênio de Melo
Unit – Faria Lima
Unit – Botucatú
São Paulo State
Located in São José dos Campos, São Paulo State.Designs and manufactures aircraft for the commercial, defense and corporate markets and provides after-sales support.
Floor space: 296,191 m² Employees at Faria Lima: 10,882
Embraer Units: Faria Lima
Sheet Metal ShopMilling
Digital ManufacturingComposite Material
Embraer Units: Faria Lima (cont.)
Final Assembly
Structural Assembly
Painting
Fuselage Junction
Embraer Units: Faria Lima (cont.)
Located in Eugênio de Melo, a district of São José dos CamposThis unit has a total area of 343,400 m², of which 54,607 m² are industrial buildings used in the development and manufacturing of tooling equipment and piping, as well as for performing welding, milling and wire looming operations.
Number of employees at Eugênio de Melo: 1,595
Embraer Units: Eugênio de Melo
Tooling – Design & Manufacturing
Tubing
Harness
Embraer Units: Eugênio de Melo (cont.)
Located in Gavião Peixoto, São Paulo State.Manufacturing facility that will host the final assembly activities of the Company´s executive and defense aircraft, as well as a runway for test flights.
Floor Space: 53,979 m²Number of employees: 1,348 Start-up of operations in October 2001
Embraer Units: Gavião Peixoto
Embraer Units: Gavião Peixoto (cont.)
Conclusion 2004 sept 1.750 m2
Cabinets Assembly Area
Legacy Interior
Executive Interior Cabinets:
Super Tucano
F5-BR Revitalization
Embraer Units: Gavião Peixoto (cont.)
Assembly Hangar
Embraer – BotucatuThe Indústria Aeronáutica Neiva manufacturing activities have been taken over by EMBRAER – Botucatu Unit, which was incorporated on July 1, 2006. The following activities are performed at the Botucatu Unit: Ipanemaaircraft production, manufacture of parts and structures for the jets of the ERJ 145, EMBRAER 170/190 and Phenom families, assembly of the Super Tucano fuselage structure, and manufacture of Ground Support Equipment tooling and devices.
Neiva will remain responsible for Ipanema aircraft marketing activities, spare parts sales and agricultural aircraft after-sales support.
Embraer Units: Botucatu
Total Area: 122,980 m²Floor space: 41,553 m²Number of employees: 1,396
Sheet Metal
Embraer Units: Botucatu (cont.)
Montagem de Segmentos
Plug Panel EMBRAER 170
EMB202 - Ipanema
Ipanema Álcool
Ground Support Equipment
Embraer Units: Botucatu (cont.)
Manufacturing Strategies
Responsiveness
Manufacturing Flexibility
Costs Reduction
Process Capability
delivery
month
LIE
LSE
Obj.
LIE
LSE
Obj.
Mtg. 3 Mtg. 4Mtg. 1 Mtg. 2 Mtg. 4Mtg. 1 Mtg. 4
1º C.C. 2º C.C.
Primary Parts
Structural Assembly
Final Assembly
Postponement:
Time-To-Market: Manufacturing Cycle Reduction
Configuration Cycle
Inventory Turn Over
4,4
6,7
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
dez/
01
fev/
02
abr/0
2
jun/
02
ago/
02
out/0
2
dez/
02
fev/
03
abr/0
3
jun/
03
ago/
03
out/0
3
dez/
03
fev/
04
abr/0
4
jun/
04
ago/
04
ALMOX. AERON. PROCESSO TOTAL
Phenom™ 100and
Phenom™ 300
Introducing a New Manufacturing
Process concept
Phenom manufacturing concept
• High performance line• Maximize activities, sub-assemblies
• Components Assemblies in parallel with the line
• “First in First Out”
• Backflushing• Automatic deduction from inventory based on
the Bill of Materials (BOM)
• Reduce the number of manual transactions
• Bonded Warehouse• Inventory management
• Planning parameter
Phenom manufacturing concept
• Fixed Workcenter per employee
• Acceleration of Phenom Assembly learning curve and maturity
• Improving the quality of the product
• Multi-functional employee, dedicated in the workcenter
• Electric and mechanical assemblies done by the same employee
• Visual Management
• Padronization;
• Easy performance evaluation;
• Clear instructions;
• Areas of material storage marked and defined;
• Quality
• Quality with Simplified Process;
• Who does, he/she makes the quality (the operator does and it verifies);
Phenom manufacturing concept
Investments&
Manufacturing expansion
Production Ramp Up
Embraer 170/190:2006 - Up to 08 ac/m2007 - Up to 12 ac/m2008 - Up to 14 ac/m
Phenom 100/3002008 2nd Half- 15 to 20 ac/y2009 - 120 to150 ac/y
70 to 78 Seats
78 to 86 Seats
98 to 106 Seats
108 to 118 Seats
Painting Shop
Final Assembly Hangar
ChemicalMilling
Surface Treatment
Facilities Investments: few examples
Embraer Logistics
ASRS System: Automated System
Automatic Storage and retrieval system for trays with integrated picking work stations
Suitable for up to 500 pick-and-put moviments per man-hour
Heigth: up to 6 m (8m Embraer Project)
Thank you