Aerospace - Cowes Facility

Jeff ArmitageVP & MD Nacelles, Cowes, Portsmouth & Yeovil

GKN Cowes - Overview

Located on Two Sites one mile apartFalcon Yard – 315,000 ft2

Osborne – 205,000 ft2

PersonnelDesign Engineers - 170Development Engineers - 30White Collar - 189Blue Collar – 562

Turnover2007 - £95m2008 - £109m2010 - £148m

Present on the Island for over 80 yearsIsland’s biggest industrial employerCompete on a global basis, from an Island base

History of GKN Aerospace - Cowes

1901 1966 1985 1994 1999

1901- High Speed Launch 1959 - Hovercraft

1969 – Black Arrow Rocket

1982 – Dash 8 Nacelles

1990 – C17 Vanes

1998 – 146 Tailplane

2002 – A380 FTE

2004 – A400M Spar

1952 – Princess Flying Boat

Design, Manufacture, Test & CertifyTurbo Fan Engine Nacelles

Turbo Prop Engine Nacelles

Composite PrimaryStructures

Composite Secondary Structures

Composite Control Surfaces

Advanced Winglets

Maintenance, Repair and Overhaul

Prime Customers

EH101 CanopyEH101 Roof PanelEH101 DV WindowEH101 Blades

A330/340 MLG And Overwing PanelsA380 Wing Trailing Edge PackageA400M Wing SparA400M Trailing EdgeA400M Inlet

C-17 Globemaster III Flap VanesC27J Spartan Nacelle

Prime Customers

Trent Fan Cowl DoorBombardier Challenger 300 NacelleGulfstream G100 / G150 NacelleDassault Falcon 50EX Nacelle

Dash 8 100/300 NacelleDash 8 400 NacelleCRJ 700/900 APU Tailcone

C130J Hercules Nacelle

Manufacturing & Development

Alenia C-27J – NacelleGKN was contracted for the complete design and build of the forward and aft nacelle in 1997 for Lockheed Martin

Contract award to first flight was achieved in 23 months

Nacelle utilises modern materials including CFRP and titanium developed for load bearing structures

Manufacturing IP developed & retained by GKN

GKN produces and delivers a fully integrated nacelle system

GKN undertook nacelle & wing fatigue certification testing

To date over 60 nacelle sets have been delivered

Aircraft has been selected for US JCA programme with expected sales of over 175 a/c

Bombardier Challenger 300 - Nacelle

Contracted by Honeywell for the design and build of the HTF7000 nacelle in 1998

Nacelle utilises latest carbon fibre materials for a high-tec low weight solution, including acoustic inlet and fan cowl doors.

Design, test, certification and LRIP undertaken by Cowes

To reduce cost; production transferred to GKN LCP partner in Poland

Engine podding transferred to GKN St Louis in line with contractual requirements for volume production

A380 – Fixed trailing Edge

Awarded the design and build contract in May 2002Involved major programme investment by GKNFinal design is 20% below the original weight requirement from AirbusLean initiatives have been incorporated from the first aircraft set in both manufacturing and logisticsAn industry leading matched part assembly process developed by Cowes (Meccano)GKN Aerospace – Cowes has developed and qualified resin film infusion (RFI) process used for the first time in civil aircraft secondary structure

Airbus -A400M WingAwarded various design and build contracts in 2004-2005Wing Spar

Aircraft set comprising of eight profiled close tolerance composite sparsA world and Airbus firstMajor programme investment by GKNATL / DDF manufacturing processFatigue Testing

Fixed Trailing EdgePackage includes composite & metallic assemblies Lean initiatives applied to each element of the packageInternational supply chain management

Engine Air IntakeLow pressure and high temperature anti-icing systemCombination of aluminium and titaniumLargest Western World Turboprop Intake

Boeing 737-300 & 767-300 Blended WingletContract awarded in 2007Contract with Aviation Partners BoeingHigh complexity component737-300 - Build to print package

High precision composite skins and spars.GKN will be capable of manufacturing 10 sets per month within 12 months of contract award.

767-300 – Design & buildWork package includes fully integrated design, development and manufacturing, including tooling

Lean initiatives are applied to the modern Design and Manufacturing processPotential follow on for the Boeing 777 and Airbus A320 winglets

Test Piece Reduction

Cowes - A Self-Contained Design, Manufacture, Certification and MRO Facility