Embraer

Industrial Architecture

        November 2006
Product portfolio

                                        ERJ 145 Series




      ERJ 135               ERJ 140         ...
Product Evolution

    ‘70s        ‘80s              ‘90s                                ‘00s

                           ...
Industrial
Operations
Manufacturing Processes
                      Raw Material                       Equipment                          Segmen...
Embraer Units
                      São Paulo State

                                                 Unit – Gaviao Peixot...
Embraer Units: Faria Lima

Located in São José dos Campos, São Paulo State.
Designs and manufactures aircraft for the comm...
Embraer Units: Faria Lima (cont.)




                Milling              Sheet Metal Shop




          Composite Materi...
Embraer Units: Faria Lima (cont.)




          Structural Assembly       Fuselage Junction




                Painting  ...
Embraer Units: Eugênio de Melo
Located in Eugênio de Melo, a district of São José dos Campos
This unit has a total area of...
Embraer Units: Eugênio de Melo (cont.)




 Tooling – Design & Manufacturing



                                    Harnes...
Embraer Units: Gavião Peixoto
Located in Gavião Peixoto, São Paulo State.
Manufacturing facility that will host the final ...
Embraer Units: Gavião Peixoto (cont.)

Executive Interior Cabinets:




                                                  ...
Embraer Units: Gavião Peixoto (cont.)




             F5-BR Revitalization




                                        Su...
Embraer Units: Botucatu
Embraer – Botucatu
The Indústria Aeronáutica Neiva manufacturing activities have been taken over b...
Embraer Units: Botucatu (cont.)




   Montagem de Segmentos




                           Sheet Metal




              ...
Embraer Units: Botucatu (cont.)




                         Ipanema Álcool




    EMB202 - Ipanema                      ...
Manufacturing Strategies
                  Time-To-Market:                                                                ...
Phenom™ 100
       and
 Phenom™ 300

Introducing a New
  Manufacturing
 Process concept
Phenom manufacturing concept

  • High performance line                             •   Bonded Warehouse
      • Maximize ...
Phenom manufacturing concept

  • Fixed Workcenter per employee
      • Acceleration of Phenom Assembly learning curve and...
Phenom manufacturing concept

  • Visual Management
      • Padronization;
      • Easy performance evaluation;
      • Cl...
Investments
      &
Manufacturing
  expansion
Production Ramp Up


 Embraer 170/190:                       70 to 78 Seats


      2006 -   Up to   08 ac/m
             ...
Facilities Investments: few examples




  Final Assembly                   Surface
      Hangar                      Trea...
Embraer Logistics
ASRS System: Automated System

    Automatic Storage and retrieval system for trays with integrated picking work
    stati...
Thank you
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Industrial EMBRAER DAY 2006

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Industrial EMBRAER DAY 2006

  1. 1. Embraer Industrial Architecture November 2006
  2. 2. Product portfolio ERJ 145 Series ERJ 135 ERJ 140 ERJ 145 XR ERJ 145 EMBRAER 170/190 Series EMBRAER 170 EMBRAER 175 EMBRAER 190 EMBRAER 195 Defense Executive ALX AEW Legacy Phenom Lineage
  3. 3. Product Evolution ‘70s ‘80s ‘90s ‘00s ERJ 140 ERJ 135 BRASILIA (EMB 120) BRASILIA ERJ 145 ERJ 145 XR BANDEIRANTE (EMB 120) (EMB 110/111) ERJ 135 EMBRAER 175 EMBRAER 170 ERJ 140 EMB 321 EMBRAER 190 EMBRAER 195 EMB 326 ERJ 145 PHENOM 300 PHENOM 100 ALX (EMB 314) AMX AMX LEGACY 600 LINEAGE 1000 EMB 121 EMB 145 AEW&C SUPER TUCANO EMB 145 AEW&C TUCANO (EMB 312) EMB 145 RS/AGS P-99 EMB 145 RS/AGS AMX
  4. 4. Industrial Operations
  5. 5. Manufacturing Processes Raw Material Equipment Segments r lie pp Su Harness Sheet Metal Machining Tubing Composite n ic ts io br ar at Fa P Sub-assembly Segments Fuselage bl al em ur y ss ct A tru S Painting System Installation and Tests Flight Preparation DELIVERY y m l se na bl As Fi
  6. 6. Embraer Units São Paulo State Unit – Gaviao Peixoto Unit – Eugênio de Melo Brazil Brazil Unit – Botucatú Unit – Faria Lima
  7. 7. Embraer Units: Faria Lima 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
  8. 8. Embraer Units: Faria Lima (cont.) Milling Sheet Metal Shop Composite Material Digital Manufacturing
  9. 9. Embraer Units: Faria Lima (cont.) Structural Assembly Fuselage Junction Painting Final Assembly
  10. 10. Embraer Units: Eugênio de Melo Located in Eugênio de Melo, a district of São José dos Campos This 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
  11. 11. Embraer Units: Eugênio de Melo (cont.) Tooling – Design & Manufacturing Harness Tubing
  12. 12. Embraer Units: Gavião Peixoto 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 m² Number of employees: 1,348 Start-up of operations in October 2001
  13. 13. Embraer Units: Gavião Peixoto (cont.) Executive Interior Cabinets: Legacy Interior Cabinets Assembly Area Conclusion 2004 sept 1.750 m2
  14. 14. Embraer Units: Gavião Peixoto (cont.) F5-BR Revitalization Super Tucano Assembly Hangar
  15. 15. Embraer Units: Botucatu Embraer – Botucatu The 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: Ipanema aircraft 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. Total Area: 122,980 m² Floor space: 41,553 m² Number of employees: 1,396
  16. 16. Embraer Units: Botucatu (cont.) Montagem de Segmentos Sheet Metal Plug Panel EMBRAER 170
  17. 17. Embraer Units: Botucatu (cont.) Ipanema Álcool EMB202 - Ipanema Ground Support Equipment
  18. 18. Manufacturing Strategies Time-To-Market: Manufacturing Cycle Reduction Mtg. 1 Mtg. 1 Mtg. 2 Mtg. 3 Mtg. 4 Mtg. 4 Responsiveness 1º C.C. 2º C.C. LSE LSE Process Obj. Obj. Capability LIE LIE Inventory Turn Over 8,0 6,7 7,0 Costs 6,0 5,0 4,4 Reduction 4,0 3,0 2,0 ALMOX. AERON. PROCESSO TOTAL 1,0 0,0 fev/02 abr/02 jun/02 ago/02 out/02 fev/03 abr/03 jun/03 ago/03 out/03 fev/04 abr/04 jun/04 ago/04 dez/01 dez/02 dez/03 Postponement: Configuration Cycle Primary Structural Final Manufacturing Parts Assembly Assembly Flexibility delivery month
  19. 19. Phenom™ 100 and Phenom™ 300 Introducing a New Manufacturing Process concept
  20. 20. Phenom manufacturing concept • High performance line • Bonded Warehouse • Maximize activities, sub-assemblies • Inventory management • Components Assemblies in parallel with the • Planning parameter line • “First in First Out” • Backflushing • Automatic deduction from inventory based on the Bill of Materials (BOM) • Reduce the number of manual transactions
  21. 21. 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
  22. 22. Phenom manufacturing concept • 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);
  23. 23. Investments & Manufacturing expansion
  24. 24. Production Ramp Up Embraer 170/190: 70 to 78 Seats 2006 - Up to 08 ac/m 78 to 86 Seats 2007 - Up to 12 ac/m 2008 - Up to 14 ac/m 98 to 106 Seats 108 to 118 Seats Phenom 100/300 2008 2nd Half- 15 to 20 ac/y 2009 - 120 to150 ac/y
  25. 25. Facilities Investments: few examples Final Assembly Surface Hangar Treatment Painting Chemical Shop Milling
  26. 26. Embraer Logistics
  27. 27. 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)
  28. 28. Thank you
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