February 2011 Page 2 - bizkaiaxede.orgBizkaiaxede.org/datos/noticias_doc/archivo26/AernnovaEng_Tou1.pdfSince 2006, the Group has organized its Engineering Activities in a Business

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February 2011

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Index

AERNNOVA ENGINEERING DESCRIPTION

Introduction

Activities

Capabilities and Services Scope

Geographical Presence

Organization

Resources

References

IT Infrastructure and Testing Facilities

Engineering Certifications

Page 4

Since its beginning, Aernnova has considered of maximum importance to have strong and flexible Product and Manufacturing

Engineering, specially in Composites where the Fabrication and Design experience combined is a Real Competitive Advantage.

Aernnova has accumulated a large experience and the recognition of Customers in the Design and Industrialization of Complete

Aerostructures, both in Composites or Metallic.

Since 2006, the Group has organized its Engineering Activities in a Business Division specialized in providing Engineering Services,

usually with Full Responsibility Workpackages, to Aernnova or to External Customers (e.g. Boeing, Bombardier, Hawker Beechcraft,

Airbus, Goodrich, etc.).

Most of the Aernnova Engineering activities are related to Design and Manufacturing of Aerostructures. The acquisition of Serra by

Aernnova in 2008, and its subsequent integration in Aernnova Engineering, has added to this division additional Aeronautical and

Automotive Manufacturing Engineering Activities.

Introduction

Page 5

• Integral Capabilities, from Weight,

and Lofting Specifications to develop:

Conceptual Design, Trade Offs, Detail

Design, Testing, Certification and

Sustaining Engineering.

• Centers in Vitoria, Madrid, USA and

Brazil.

• Complete Work packages or

Technical Assistance.

• Design Organization Approval (DOA)

by EASA.

• > 7 million hours experience.

• Design and Automation of:

Aerostructures Assembly Lines

Composites Manufacturing

Systems.

Tooling and Advanced

Manufacturing Processes.

• Manufacturing Engineering Support.

• > 1 million hours experience.

Aeronautical Engineering Automotive Engineering

Aernnova Engineering

Product Engineering Manufacturing Engineering

• Design and Turn Key Delivery of

Automotive Assembly and Welding

Lines.

• Design, Analysis and Simulation of

Automated Solutions.

• Welding Guns, Electronic Controls

and Machines.

• Transformers.

• Bolt and Nut Feeders.

• Technical Assistance

Automated Assembly Lines Welding Systems

902 Employees

626 Employees 276 Employees

Activities

+64 Contractors mainly in Product Engineering = 966 Total Resources

Page 6

− Integrated Customer

Services (ICS)

− Repair DOA, POA, MOA

− Aircraft on Ground

Support, AOG 365d/ 24h

− Maintenance Support

− Technical Publications

− Material Review Board

− Production Non

Conformities Disposition

− Aerostructures Assembly

Lines

− Composite

Manufacturing Systems

− Tooling and Advanced

Manufacturing Processes

(Design, Set Up and

Fabrication Support)

− Lean Manufacturing

− Training and Transfers

− Liaison with Airworthiness

Authorities

− Materials & Processes

− Certification Tests Analysis

− Systems and Vendor Items

Qualification

− Internal & External Audits

− Certification DOA, MOA,

POA

− Certification Compliance Plan

Definition & Follow Up

− Integral Test Management

− EMI/EMC/ Lightning

− Test Results

− Material Qualification

− Leakage & Pressure tests

− Flight Test Instrumentation

− Flight Test Support

− Endurance

− Fire, Smoke

− Ground Test, etc.

− Performances

− Aeroelasticity

− Flight Physics

− Loads Analysis

− Preliminary and

Conceptual Design

Aernnova Engineering provides Integral Capabilities from Preliminary and Conceptual Definition to Product Support, and a Flexible Scope of

Services along the Project Life Cycle Complete Workpackages, Technical Assistance and Programs Management Support.

Aernnova is an approved organization for design (DOA), production (POA) and maintenance (MOA) as certified by Airworthiness Authorities.

Testing CertificationManufacturing &

AssemblingProduct Support

Design and Development

Prelim. & Conc. Definition

Projects Management (Multisite IT Infrastructure)

Engineering Capabilities and Services Scope

− Structures Design (Metallic

& Composite)

− Systems Design

− Weight Control Manag.

− Damage Tolerance

− FEM Modelling

− Thermal Analysis

− Mechanisms Definition

− Structural Repair Manuals

− Test Plans

− Materials Engineering, etc.

- Concurrent Engineering

Page 7

In parallell to the Main Activities (Product and Manufacturing Engineering) , Aernnova Engineering integrates other Technical Assistance

Activities, organized as well as Specialized Business Units, with the aim to:

Increase Flexibility, Quick Reaction Capacity and Competitiveness.

Support the Growth

Additional Business

Technical Assistance Services

ARGHOS TECHNICAL ASSISTANCE

‒ Engineers or Groups Support

‒ Product, Systems and Manufacturing

Engineering

‒ Customers:

• Aernnova

• External: 24 (40 % Revenues)

‒ Sectors:

• Aeronautics

• Energy

• Trains

• Defense

STAFFING IT SERVICESPERSONNEL AND TRAINING

MANAGEMENT

STRELIA

‒ IT Infrastructure and Multisite Systems

‒ PLM / ERP Integration

‒ Managed Services, Provider

‒ Customers:

• Aernnova

• External: In progress

‒ Sectors:

• Aeronautics

ARGHOS CONSULTING

‒ Personnel Management:

• Recruitment

• Organization

• Expatriates

‒ Training Management

‒ Customers:

• Aernnova

• Objective to Expand

‒ Sectors

• Aeronautics

Page 8

The Engineering Division is developing a Global Footprint:

― Aeronautical Product Engineering: Spain (Vitoria and Madrid), USA, Brazil (India in the 1st Half 2011).

― Aeronautical Manufacturing Engineering: Spain (Vitoria and Barcelona) and Romania.

― Automotive Engineering: Spain (Barcelona) and Brazil.

Geographical Presence

Page 9

Organization


Pedro Fuente

Product EngineeringAES

J. Ignacio Ibarreche

Vitoria Fernando Campo

MadridM.A. Castillo

USAJ. Carlos Ortiz

BrazilAdel Ben - Smida

Support Services

IT ServicesStrelia

J. Angel Bravo

Training and Personnel Management Arghos Consulting

Elena Yeregui

Manufacturing EngineeringAME/Serra

Javier Tapuerca

AeronauticalManufacturing

Engineering

Technical AssistanceArghos Technical Assistance

Marc Salomon

AutomatedAssembly Lines

WeldingSystems

Aernnova ManufacturingEngineering

AMEAbelardo Serrano

Serra AeronauticsAlejandro Peña

RomaniaSantiago Otegui

Serra AutomotiveTheo Slangen

PyssaAnselmo Sells

Serra SoldaduraJavier Tapuerca

ElesaPablo infante

Serra Do BrasilRafael Ronconi

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AES (Aernnova Engineering Solutions)

Product Engineering Organization

MANAGING DIRECTORJ.I. Ibarreche

HUMAN RESOURCES DIRECTOR

J. Menor

FINANCE & ECONOMIC DIRECTOR

F. MolásSYSTEMS COMERCIAL

DIRECTOR

A. Esquisabel

CERTIFICATION , TEST & QUALITY DIRECTOR

P. Verdugo

DESIGN & WEIGTHS DIRECTOR

P. Alvarez

STRESS ENGINEERING DIRECTOR

F. Rebollo

PROJECTS MANAGEMENT & CONFIGURATION DIRECTOR

J.I. Uriarte

ENGINEERING SUPPORT &

MATERIALS DIRECTOR

I. Moreno

AES VITORIAMANAGING DIRECTOR

F. Campo

AE BRASILMANAGING DIRECTOR

Adel Ben-Smida

AES IBERICAMANAGING DIRECTOR

M.A. Castillo

AE US MANAGING DIRECTOR

J.C. OrtizCHIEF OF MATERIALS &

PROCESSES J.Valer

MRB METALIC NORTH

B. Arrausi

MRB METALIC CENTRE

J.A. Romero

MRB COMPOSITE NORTH

E. S. De Argandoña

ENGINEERING MANAGERBOEING CLIENT

J.Rodriguez

ENGINEERING MANAGER BOMBARDIER CLIENT

P.Pomar

TESTING MANAGEMENTS.Anaya

DATA & DOCUMENTATIONSERVICES

LABORATORY

MRB COMPOSITE CENTRE

I. Velasco

COMERCIAL DIRECTOR

A. Martinez

TECHNOLOGICAL DEVELOPMENT MANAGER

I. Otero

TECHNICAL DIRECTOR

E. Belotto

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AME / SERRA (Aernnova Manufacturing Engineering)

Manufacturing Engineering Organization

Manufacturing EngineeringAME/Serra

Javier Tapuerca

AeronauticalManufacturing

Engineering

AutomatedAssembly Lines

WeldingSystems

Aernnova ManufacturingEngineering

AMEAbelardo Serrano

Serra AeronauticsAlejandro Peña

RomaniaSantiago Otegui

Serra AutomotiveTheo Slangen

PyssaAnselmo Sells

Serra SoldaduraJoaquin Suazo

ElesaPablo infante

Serra Do BrasilRafael Ronconi

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PhD+ MSc 492

BSc 150

Prof .Educ. 260


Aeronautical Engineering Automotive Engineering

Product EngineeringManufacturing Engineering

Automated Assembly Lines

WeldingSystems

626 Employees

532 94 120 156

276 Employees

Distribution of Total Resources 966 by Type of Contract

Distribution of Employees by Level of Education

Distribution of Employees by Professional Levels

Tech. Mgr., Engineers or Technicians

652

Staf f92

Manual Workers

158

902 Employees

Resources

Permanent 794

Eventual 108

External 64

Data january 2010

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Aeronautical Engineers and Technicians

Employees Breakdown by Disciplines

Resources

Design 224 Factory Support Engineering 25

Stres 179 Tooling Designers 33

Engineering Quality Certification &

Testing10

Manufacturing Processes

Engineering32

Conf. Control & Project Management 17 IT and Other Technicians 32

Materials and Special Process

Engineering10 Management & Other Overheads 64

Discipline # Discipline #

TOTAL = 626 Aeronautical Engineers and Technicians

Data january 2010

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Aeronautical Engineers and Technicians

Design and Analysis Employees Breakdown

DesignEngineer V

> 15 yr

Engineer IV

> 10 yr

Engineer III

> 7 yr

Engineer II

> 4 yr

Engineer I

> 2 yr

Technical

DesignersTOTAL

Composite Structures

Design5 8 15 5 2 36 71

Metallic Structures

Design8 15 30 11 2 70 136

Mechanisms Design --- 2 5 3 4 3 17

TOTAL 13 25 50 19 8 109 224

AnalysisStress Engineer V

> 15 yr

Stress Engineer IV

> 10 yr

Stress Engineer III

> 7 yr

Stress Engineer II

> 4 yr

Stress Engineer I

> 2 yrTOTAL

FEM (Loads) 3 5 8 8 --- 24

Stress Metallic 6 8 31 35 3 83

Stress Composites 6 7 12 13 3 41

Stress Mechanisms --- 1 8 8 --- 17

Fatigue and DT 1 3 5 5 --- 14

TOTAL 16 24 64 69 6 179

Resources

Data january 2010

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IT Tools

Testing Facilities

W/S & Catia Pc´s 531

PDM I-MAN

CAD CATIA, PRO ENG.

FEM PATRAN NASTRAN Promech., Dytran

CRAK. PROP. Fracture Research, Nasgro

Other Transcendent Fibersim, Matlab, Own Software

Materials ANN Lab EUITA INASMET

Structures CTA

Fire CTA

Other CTA - HALT / INTA / CEAT

IT Tools and Testing Facilities

ISAMI

Data january 2010

Page 16

Software

Design (Structures and Systems)

― CATIA V4 & V5.

― Fibersim.

Structural Analysis:

Static & Dynamic (MSC-Nastran/ISAMI)

Pre- Post Processing- Patran, Hypermesh.

Non Linear Analysis- ABAQUS, MSC- MARC.

Impact Analysis (MSC-DYTRAN, ABAQUS).

Weight Reduction Optistruct.

PDM (Product Data Management) iMan V5&V7(UC)

Materials and Processes

Development of Standards and Specs.

Materials and Processes Qualifications

Simulation

DELMIA

Robcad

CAM Software

Unigraphics

CATIA

Software and Multisite System

Page 17

Wings

Embraer

• Complete Wing:

• Wing Box

• Leading Edge

• Trailing Edge

• Wing Tip/Winglet

• Control Surfaces: flaps, ailerons, spoilers.

• Systems: Electrical, Fuel, Hydraulics, Flight Control,

Anti-ice and EMI/EMC

Customer Aircraft Work Packages Scope

Boeing • B747-8• Wing Box: Spars, Skins and Stringers.

• Control Surfaces: Spoilers and Ailerons.

• Detail Design

• Certification Support

Product Engineering Main References

Hawker

Beechcradt

• Premier Hawker

Family• Wing Box, Leading Edge, Trailing Edge, Wing

Tip/Winglet, Control Surfaces and High Lift Devices.

• Conceptual and

Preliminary Design

• Concept Trade offs

• Optimal Solution

• ERJ-145 Family

• Conceptual Design

• Detail Design

• Testing

• Certification

• Prototypes

• Liaison Engineering

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Embraer• EMB- 170/190

• Complete Horizontal Stabilizer:

‒ Main Box Structure

‒ Elevators

‒ Systems Provisions

‒ Ground and Flight Test Instrumentation


• Preliminary Design

• Detail Design

• Testing

• Certification

• Prototypes


Bombardier• CRJ700/900/

1000 Family

• Complete Horizontal Stabilizers


‒ Elevators


• Detail Design (only

900/1000 version)

• Engineering Support


Airbus• Airbus 350

XWB

• Complete Horizontal Stabilizers


‒ Elevators

‒ Electric and Hydraulic Systems Design

‒ Ground & Flight Test Instrumentation



• Detail Design

• Testing

• Certification

• Prototypes


Horizontal Stabilizers



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Embraer• EMB-170/190

Family

• Complete Vertical Stabilizers

‒ Main box structure

‒ Rudder

‒ Systems provisions

‒ Ground and flight test instrumentation



• Detail Design

• Testing

• Certification

• Prototypes


Bombardier• CRJ 700/900/

1000 Family

• Complete Vertical Stabilizers



• Detail Design (only 900/1000

version)

• Engineering Support


Vertical Stabilizers



Page 20

Embraer• EMB-170/190

Family

• Complete Rear Fuselages

‒ Main structure




• Detail Design

• Testing

• Certification

• Prototypes


Bombardier • C Series

• Tail Cone

‒ Main structure




Airbus • A 380

• S19 Internal Structure


‒ Ground and Flight Test Instrumentation


• Detail Design

• Testing

• Certification

• Prototypes


Boeing • B 747 LCF

• Rear Fuselage (Swing Zone)

‒ Fuselage Structure

‒ Mechanisms for Folding

‒ Provisions for Latches


• Detail Design

• Manufacturing Support

Rear Fuselages



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Boeing • B 747-8

• Section 42 FWD & AFT

‒ Main Structure


• Detail Design


Bombardier

• C Series

• Center Wing Box:

‒ Full Composite Structure


‒ Ground and Flight Test instrumentation



• Detail Design

• Prototypes

• Material Qualification

• Design Allowable

Embraer • ERJ-145 Family •Belly Fairing



• Detail Design

• Testing

• Certification

• Prototypes


Central Fuselage and Fairings


• Bullet Fairings • Aerodynamic Shaped Composites Panels

• Detail Design

• Certification



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Sikorsky • S-92

• Horizontal Stabilizer

‒ Composite Main Box

‒ Flight Test Instrument



• Detail Design

• Testing

• Certification

• Prototypes


• Aft Transition Tail Cone

• Fuselage Structure

• Composite Ramp

• Mechanics

• Main rotor pylon:

‒ Composite Structure

‒ System Interfaces

‒ Cabin Interfaces

‒ Engines Cowling

‒ Engine Exhaust

•Civil and Utility Interiors:

‒ Composite Supporting Structure, Ceiling Panels,

Electrical System Installation, Air Condition Ducts,

Fire Extinguishing Systems

Helicopters


• Systems Installation

• Ground & Flight Tests

Instrum.

• Folded & Mechanism


Page 23

Flightech

Systems

• ALTEA

(MTOW 75 Kg.)

• Aerodynamic Shape and Loads Definition

• Performance Analysis

• Complete CFRP Structure Design:

‒ Fuselage

‒ Wing

‒ Empennage

‒ Front and Main Landing Gear

• Servo-actuators Definition

• Engine, Fuel Tank and Parachute Integration

• Prototypes Manufacturing

• Aerodynamic Design



• Detail Design

• Testing


• Manuf. Engineering


Avibras• FALCAO

(MTOW 600 Kg.)

• Complete CFRP Structure Design:

‒ Fuselage

‒ Wing

‒ Empennage

‒ Front and Main Landing Gear

‒ Engine, Fuel Tank and Parachute Integration



• Detail Design

• Manuf. Engineering


UAV´s



Page 24

Others

Embraer • RJ-145 Family

• Thrust Reverser

‒ Fixed Structure

‒ Systems Assembly

‒ Blocking Doors

Airbus • A350 XWB

•Pressure Bulkhead MLGB

‒ Complete Composite Structure

‒ Provisions for Systems

Eurofighter • EF-2000•Flare Dispenser

‒ Composite Solution


• Detail Design

• Testing

• Certification

• Prototypes


• Concept Design


• Detail Design

• Testing

• Certification

• Prototypes



• Detail design

• Testing

• Certification

• Prototypes

• Liaison engineering



Documents

February 2011 Page 2 - bizkaiaxede.orgBizkaiaxede.org/datos/noticias_doc/archivo26/AernnovaEng_Tou1.pdfSince 2006, the Group has organized its Engineering Activities in a Business