AEROSPACE ENGINEERING –WORKING AGAINST GRAVITY

AVIATION DIVISION

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Designers and computational engineers, development and test engineers, systems and simulation experts, systems architects and programmers: you need a great variety of experts in the aerospace sector. As our customer, you are entitled to expect that you will always work with the top talents in your field. An attitude that we understand only too well.

Personal technical competenceOur focus is always to ensure that our experts are qualified for the task in hand. Our employees are subjected a strict selection procedure, after which we encourage them to continually increase their knowledge and experience and offer them posts that remain attractive in the long term. You will meet aerospace specialists with outstanding know-how and experience, as well as great flexibility and motivation to add that extra lift to your project at our centres of competence.

COMPANY

Professionally managed processesStandards and expectations in the aerospace industry are especially high, and the inter-dependencies are very complex. Both operationally and technically, we focus 100 per cent on your processes and offer you high- quality, efficient solutions appropriate to your needs. These incorporate the toughest safety requirements, covering development across inter national borders while operating under enormous pressure to work efficiently. Our awards and certifications from major aerospace companies confirm that we are the experienced and reliable partner who provides you the freedom to pursue your designs and long-term development scope for the future.

WE GIVE YOUR DEVELOPMENTS THE LIFT THEY NEED

We are there where you need us

Whether at our centres of competence with projects of our own or working locally on your premises: we are there for you at the industry’s key hubs. The AVIATION division has offices at all the aerospace industry’s most important locations. Moreover our transnational partner network combines excellent know-how with extremely reasonable terms.

Division management Locations Project teams

Born in 1966, airborne since 2004

FERCHAU’s engineering services division first saw the light of day in 1966, then in 2004 the AVIATION division was split off to form a separate business unit in order to concentrate its specific expertise even better than before. We are present at all the important aerospace industry locations throughout Europe.

For you, this means that you can rely on a sound, professional company that knows precisely what it is doing. We are fully aware of the requirements of the aerospace industry, and we also know how to fulfil them.

. Specialises in engineering for the aerospace industry

. FERCHAU was founded as a company in 1966

. Separate AVIATION division since 2004

. Pan-European presence . More than 800 employees

in the division . Certified to EN ISO 9100

as well as other industry standards

. Airbus Group Preferred Supplier for Engineering & Customer Services

Fact check FERCHAU AVIATION

A selection of our experts’ qualifications:

. Aviation engineers . Computer scientists . Business engineers . Mechanical engineers . Electrical engineers . Communications engineers . System engineers . Software engineers . Civil engineers . Material science engineers . Draughtsmen/women . Technical writers

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Because we know our way around the civil and military aerospace industry so well, we are able to provide a direct advantage for your projects. That is why Airbus Group selected us as a Preferred Supplier for Engineering & Customer Services, for example and also why we are preferred suppliers for many other customers, too.

Partner is more than merely a catchphrase for usApart from detailed knowledge and specialised know-how, various other factors are also vital for successful cooperation. Firstly, our size and independence make us a stable, reliable partner in the long-term. But our capacity for long-run strategic thinking, which brings your projects greater success – because as a rule neither you nor we are interested in short-term solutions but in enduringly viable concepts is equally important.

EXPERTISE IN AVIATION

Ready for take-offPart of our job is of course always to be up to date with the latest state-of-the-art technology and be fully aware of statutory requirements and relevant procedures. No matter whether it concerns development methods, manufacturing processes for lightweight construction or international testing standards and acceptance procedures: FERCHAU AVIATION employees provide the ideal mix of knowledge, experience and competences to generate the optimum solutions.

TAKING YOUR PROJECTS TO CRUISING ALTITUDE

FERCHAU AVIATION supports you in your daily work via three key facets of our expertise:

Airframe & structures . Primary and secondary

structures of aircraft . Design . Stress . F&DT

Consulting . Project management . Risk management . Configuration management . Supplier management . Supply management

Engineering competence

Work packages in competent hands. We put the necessary organisation in place for you and take care of the work at an agreed cost. We are also happy to assist you right from the outset during the project specification phase: we integrate highly specialised partners for this through our network.

Engineering support

Putting external resources to flexible use. Our employees complement your development team to help cope with peak order volumes, capacity bottlenecks and special projects. Thus you benefit from expert support while retaining full flexibility without placing a lasting strain on your budget.

Managed services

Leave all your capacity management to us. If your expenditure on coordinating service providers is rising, allow us to take over management for you. We will improve the quality and transparency of the associated processes and you can concentrate on your projects.

Cabin & interiors . Customised engineering . Conversion & completion . Design & stress

Manufacturing engineering . Jigs & tools . NC programming . QA . FAL . MAP

Systems engineering . MBSE, RBE . Functional design . Simulation & control . MSI, FTI . Avionics

Range of services

Our breadth of know-how in the aerospace sector is vast. Tap into this highly specialised knowledge for the benefit of your development projects.

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Model-Based Systems Engineering

Project Managem

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Quality Assurance Management

Performance Qualification

System Development & Configuration

User Requirements

UnitAIT

Configuration & Technical Specifications

Installation Qualification

ValidationTraceability

FunctionalRequirements

Operations Qualification

ValidationTraceability

Detailed Design

ValidationTraceability

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CORE AREAS OF EXPERTISE

CLEAR FOR TAKE-OFF TO ACHIEVETOP DEVELOPMENT RESULTS

Primary and secondary structure

It is becoming harder and harder to make aircraft lighterEverything that flies has already become a lot lighter in recent years. Saving weight in aircraft without having to compromise in terms of stability and security is therefore the trickiest issue of all. Our experts help to square the circle by making good use of their knowledge of new materials, new production processes and bonding techniques and by employing innovative design and dimensioning methods.

Connections made easySecondary structure components must make do with tight design spaces and cope with complex cable runs. With that in mind, our experts design all the attachments and connections, cable routes and system sections so that there is space for everything – and everything stays in place despite all the vibra-tions. New materials, in particular, often bring new challenges in their wake: joining plastic parts to aluminium components demands new ways of working. FERCHAU AVIATION employees have the necessary know-how from various projects to find the right solution.

Flight Test Installation (FTI)

Testing is the way to goFlight tests with the first few prototypes of a new aircraft model are never routine: how will the landing flaps behave in actual flight? Do the wingtips vibrate too much at high levels of thrust? Each aircraft has its own specific flying characteristics and needs specially adapted tests and measurements. Our experts help you to generate all the vital data and produce the necessary findings, for example by using cameras to record visual evidence and taking measurements with sensors.

The flying laboratoryFor these test flights our engineers install complete computer centres on board, along with several dozen cameras and sensors, all of which have to be fitted onto special substructures in the extremely confined design spaces. The test equipment can quickly weigh up to several tonnes – and many kilometres of measuring cables must be laid too. The on-board measuring technology not only must withstand the acceleration forces on take-off and landing, but also the forces encountered during flight manoeuvres, which often go beyond the usual limits during test flights.

. Initial and detailed design . 3D modelling . Stress analysis . Fatigue & damage

tolerance . Surface optimisation . Weight reduction . Optimum-cost design

Project abstractOn behalf of a major aircraft manufacturer, specialists from FERCHAU AVIATION assumed responsibility for the FTI equipment for six aircraft. The individual requirements in terms of the measuring instrument hardware and the entire cabling process were different for each aircraft. The installations were therefore first produced as a digital mock-up, from which the derivations were made in 2D for manufacturing and assembly. The project is scheduled to run until 2016 and is all proceeding fully in accordance with plans and has impressed all conncerned in every respect so far.

Project abstractFERCHAU AVIATION employees develop critical structural components, e.g. the pylons in the primary structure for one of our customers. They also design and calculate secondary structure elements such as brackets or door frames. It goes without saying that they also handle the preparation of the subsequent component drawings and obtain approvals for the components, as well as providing manufac-turing support (concessions & DQNs) and optimising the weight.

. Detailed design . Flight-ready mounting

and verification . Computer systems . Camera systems . Sensors and measuring

instruments . Evaluation systems . Trimming systems

10,000 signals simultaneouslyAll of the measurement data, signals and images are processed and collated in real time in the FTI system. While the flight is still in progress they are sent to the flight test engineer on board or to the test centre on the ground. The number of signals generated per second can easily reach 10,000 – all occurring simultaneously. From subsequent analysis of the data you can then see where further action is required and where your design already meets the aviation authority’s strict requirements, safety standards and guidelines.

Ensuring that damage doesn’t mean disasterTo minimise risks, we develop concepts for our customers specifically aimed at improving failsafe characteristics. These include redundant, fault-tolerant components designed for the longest possible service life. New technologies always pose new challenges for the design engineers, too. One task for our experts, for example, is to inspect carbon fibre composite elements for possible damages not visible to the naked eye, analyse the causes and devise counter-strategies.

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Cabin & cargo

Comfort is the hardest work of allEverything that passengers subsequently enjoy in terms of maximum comfort costs a lot of effort in design and development. Cabin systems such as air conditioning, lighting, power supply and infotainment systems are becoming more complex and have to be fitted into the tight spaces in the cabin, as well as being interconnected. On top of that, everything should be easy to use and be attractively designed. This may not be easy in a passenger jet for scheduled airline services, but in business jets or VIP aircraft it becomes a real challenge. This is why our engineers often design the entire cabin concept when it comes to fitting out this kind of jet, because that is the only way to meet all the requirements satisfactorily.

Electronic systemsOn-board internet, in-flight entertainment and communications systems all have to be robust, safe, convenient and easy to operate. Our engineers develop electronic systems that stand up to even the toughest conditions for your aircraft. Temperature fluctuation, acceleration, vibrations and heavy use by passengers are no problem for them.

. Cabin interiors . Communication systems . Supply systems . In-flight entertainment

(IFE) . Cargo compartment . Cargo loading system

Project abstractCompletely redesigning the main deck of a cargo aircraft presents our development experts at the Laupheim engineering office with a fascinating set of tasks. The team designs sidewall panels in the upper and lower deck fuselage, dado panels and dado angles. They also come up with perfectly adapted solutions for the cylindrical or conical areas of the aircraft.

Logistics in the airThe cargo area in both freight and passenger aircraft is set up to cope with extremely fast logistics processes. Given the large quantities of cargo that even passenger jets transport nowadays, there is greater expectation of fully automated cargo loading systems with air-conditioned and specially secure zones. Airlines now demand fast loading and unloading, safe stowage during the flight even under turbulent flying conditions, air condi-tioning in the cargo hold for the transport of live animals and simple determination of the centre of gravity during the loading process. Our experts ensure that your luggage and cargo will also arrive safely.

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Systems engineering

End-to-end developmentWe base our work on the latest model-based systems engineering methods. This means that we derive specifications and system definitions from model simulations in order to avoid having to make changes in the development cycle, therefore reducing development costs. By employing end-to-end methods in devel-opment, we ensure that problems are detected at an early stage and any resultant changes are implemented straight away. We then ensure that all the necessary adjustments are consistent and adapt the relevant verification tests.

Redundancy and fault toleranceWe make no compromises when it comes to systems like the Aircraft Condition Monitoring System (ACMS) or the Digital Flight Data Recording System (DFDRS). Data must constantly be collected and recorded safely and reliably. Our experts are experienced in designing these systems to be fault-tolerant and redundant and with adapting them to suit individual aircraft. Appropriate tests and simulations ensure that the systems are robust and will perform as required.

. Model-based systems engineering

. Requirements-based systems engineering

. Functional design & simulation . Verification, validation & test . Simulation . ILS/RAMS . Studies

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Project abstractWe are actively involved in the ACMS for two new aircraft models from a major aircraft manufacturer. Experts from FERCHAU AVIATION are working with the client to define quality benchmarks, test procedures and integration and operation tests. In order to facilitate the performance of these tests, they have also created an appropriate test environment.

When development and operation mergeEven simple systems hold considerable potential for improvement, especially when you consider that the demand for smooth oper - ation is dominating development more and more. Subsequent maintainability and the availability of systems without particular maintenance requirements are crucial factors which contribute to a system’s operating costs, for example. Our engineers are well versed in these issues and take account of the latest findings from ILS and RAMS when developing the systems.

Winning time and againIn the annually conducted top ranking of the 100 most attractive employers by final year students and graduates (Engineering Edition), FERCHAU is again the best-placed engineering services provider. In 2014, this already made us the most popular employer in this market segment for the ninth year in succession.

We were also the best engineering ser-vices provider according to the employer attractiveness ranking carried-out by the Universum Communications consultancy. Some 32,000 students were interviewed for the Engineering Edition and voted FERCHAU to an excellent 49th place in the top 100.

FERCHAU strikes goldTogether with the news magazine Focus, the largest German-language employer assessment portal Kununu has distin-guished us as the best German employer in the category “Personnel Services Providers – Top 5 Large Employers”

This award has proven that our employees enjoy a positive approach to our diverse and uninterrupted commitment to be attractive as an employer.

Customer certificationNot only long-term customer relationships indicate that customers are satisfied. Companies operating on a global scale demand that their service providers and suppliers engage in uncompromising quality management with regular audits. Above and beyond this, numerous customers have expressed their confi-dence in us by raising us to the status of Preferred Supplier. The reasons for this normally stated by our customers are our smooth project management, our excellent record in keeping to deadlines, our commitment and our supply man-agement’s ability to cope with pressure.

POWER OF PERSUASION

FIRST CLASS FOR ALL ORDERS

Everyone at FERCHAU AVIATION knows that it is down to them and their work to ensure that the ultimate outcomes achieve the excellence required. The fact that we are aware of this responsibility is apparent from the outstanding ratings we repeatedly receive from customers, employees and internal and independent testing organisations.

It is those independant testing organisations that we have our high standards of quality and safety tested by to their limits. Not only is this a necessary prerequisite for obtaining certifi-cation such as EN ISO 9100 and various other industry standards, but it is also a constant incentive for us not merely to be good, but to be better.

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Customers, applicants and independent testing organisations have very high expectations. Convincing all of them of our capabilities is a race that is almost impossible to win. But only almost.

Quality assurance: the internal Q teamOur internal quality team is on the move almost every day, not only to ensure quality but also to keep further refining it on a constant basis. They visit each of our sites twice a year, and subject all the processes and procedures to a pain staking examination – including our applicant management system.

Optimising quality is an ongoing process at FERCHAU AVIATION. We regularly subject ourselves to scrutiny by using tools such as customer satisfaction analyses and employee attitude surveys.

If you would like to find out more about FERCHAU AVIATION, there are various ways of getting in touch. We would like to invite you to get to know us better and see for yourself how well we can support you.

Your direct contact is a fellow professionalOur sales staff are the best example of our understanding of what quality means. It is hugely important to us that you are able to communicate with them at the appropriate specialist level – therefore our sales employees are all graduates in scientific subjects. This means that they immediately understand how they can help you, what qualifications are needed and how long the project is likely to take.

Our references speak for themselves – and for FERCHAU AVIATIONWe have worked in the aerospace industry for several decades now, so a vast array of renowned enterprises have enjoyed cooperat-ing with us. Our project reports are brief and to the point, providing you an impression of our procedures and our work style. Please contact us if you would like to have further information.

INFORMATION

THE DIALOGUEHAS ONLY JUST BEGUN

Always up to date with developmentsNaturally you can also find further interesting details on our website aviation.ferchau.de, or in our AVIATION NEWS which we publish at regular intervals. We would also be more than happy to send our regular newsletter to your e-mail address if you take the trouble to go through the brief registration process.

Your direct route to FERCHAU AVIATION: AVIATION.FERCHAU.DE

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FERCHAU Engineering GmbHHead OfficeSteinmüllerallee 251643 GummersbachGermanyPhone +49 2261 3006-0Fax +49 2261 3006-99info@ferchau.deferchau.de

FERCHAU Engineering GmbHAVIATION DivisionDivision ManagementButendeichsweg 221129 HamburgGermanyPhone +49 40 3176157-0Fax +49 40 3176157-9aviation@ferchau.de

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