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Inbra aerospace info 11 2011
- 2. IN A NUTSHELL • 100% Brazilian company; • Founded in 1979; • Total area : 160.000 m2; • Production area : 23.000 m2; • Direct employees : 570;
- 3. ORGANIZATION
- 4. DEFENSE MARKET • Inbra has initially focused in the domestic defense market; • Developments in the global market have started some years ago, in a very competitive environment; • Experience gained in the last 20 years has allowed to improve in raw materials, processes and products.
- 6. • Parts in composite materials; – Carbon fiber – Aramid fiber – Glass fiber – Sandwich parts • Transparent parts for aeronautics; • Armored cockpit doors. • Armoring for helicopters and aircrafts.
- 7. GENERAL INFORMATION • Existing production area: 3.500 m2; • Production capacity: – 15.000 manhours (currently available); – 20.000 manhours (expected till dec 2012); • Available area for additional immediate expansion: 4.500 m2; – Allows us to go up to additional 30.000 manhours.
- 8. GENERAL INFORMATION • Number of direct employees: 100, with forecast to increase to 170 througout 2014; • Personnel breakdown: – 5% quality; – 5% development – 5% process; – 10% PPC – 3% administration; – 72% production.
- 9. GENERAL INFORMATION • Engineering support – For process: • In-house. – For products: • Outsourced in São José dos Campos (Akaer).
- 10. AERIAL VIEW
- 11. THE PLANT Our facilities include: – Clean room with 400 m2; – Freezer with 117 m3; – Fully automated environment control (by software); – Painting room with 50 m2; – 2 automated control autoclaves; • # 1: Diameter 1,7 m x 6,4 m;
- 13. CLEAN ROOM – MANUFACTURING OF AEROSPACE COMPOSITES
- 15. AUTOCLAVES FOR CURING OF AEROSPACE COMPOUNDS
- 16. QUALITY ROOM
- 17. FREEZER FOR PREPREG STORAGE
- 18. HONEYCOMB DRILLING & DRY SANDING Solid residues pick up Area: 25 m2
- 19. PAINTING ROOM & OVEN
- 20. PAINTING ROOM • Doors dimensions: – Entrance and exit of the part: • Inside width: 4.000 mm • Inside heigth: 3.200 mm • Cabin dimensions: – External length: 9.560 mm – External width: 5.000 mm – Inside height: 3.300 mm – External height: 4.000 mm
- 21. PRODUCT LINE • Composite material parts with aerospace prepreg technology made in: – Carbon fiber – Aramid fiber – Glass fiber – Nomex honeycomb
- 22. EXAMPLES OF COMPOSITE MATERIAL PARTS FOR AEROSPACE COMPANIES
- 23. EXAMPLES OF COMPOSITE MATERIAL PARTS FOR AEROSPACE COMPANIES
- 24. EXAMPLES OF COMPOSITE MATERIAL PARTS FOR AEROSPACE COMPANIES
- 25. PRODUCT LINE • Aircraft armoring: – Embraer armored cockpit door – Level III-A NIJ; – Armoring against ammunition 0.50” AP – M2, according to MIL-STD-662, for Embraer´s Super Tucano. – Helibras armored parts for Esquilo (AS 350) helicopters. – Elbit´s UAV composite parts (Hermes 450)
- 26. ARMORED COCKPIT DOOR EMB 170/190
- 27. ADHESIVE FILM ALUMINUM SHEET LAMINATED DECOR LAMINATED DECOR PRE-PREG WOVEN HONEY COMB BALLISTIC WOVEN MULTIPLE USE OF ARAMID FIBERS
- 29. ARMORING FOR 0.50” AP EMBRAER SUPER TUCANO
- 30. PRODUCT LINE • Transparencies for special windows.
- 31. TRANSPARENCIES Canopy Observation window
- 34. QUALITY • NBR ISO 9001 : 2008; • NBR 15100 : 2004 / SAE AS 9100 B for aerospace segment; • Effective May 2005; • Certification agency: CTA (Aerospace Technical Center – Brazil). • NBR ISO 14001:2004 – May 2012 • AC 7118 B (PRI NADCAP) – May 2012
- 35. CERTIFICATIONS
- 36. CERTIFICATIONS
- 37. CAPABILITIES – Expansion of production capacity and infra- structure; – Modernization of tooling and equipment; – Expansion of raw material procurement; – Workforce growth with adequate training; – Diversification of product line into primary aicracft structures, composite and composite/metal assemblies; – Tooling development and manufacturing.
- 38. NEW BUSINESSES • Composite aerostructures – Embraer new projects; • KC 390 – UAV parts manufacturing; – Helicopters; • Assemblies • Armoring – T1/Gripen consortium • Wings • Main Landing Gear Doors
- 39. EUROCOPTER/HELIBRAS EC 725 Composite parts and intermediate composite structures. Contract signed In October 2010.
- 41. NEW BUSINESSES • Evolution from services provider to integrator; – Through partnerships of technology transfer.
- 42. WHAT WE HAVE DONE IN TECHNOLOGY TRANSFER • Development and implementation of armoring installers in Brazil; • Armoring services for passenger cars in Mexico and Argentina; • Solutions for helicopters armoring in Colombia.
- 43. Business Maturity Defense mkt Interaction Armoured cockpit Door development Glass forming; Special armouring; Composite mnfg. Complete Airframe; Integration; JV´s Consortium Composite New plant Vehicle development NG Vehicle Aramid development processing Armouring Filters Aramid Vests, shields... moulding 1979 1993 2002 2010 Timeline
- 44. THE FUTURE • Technology transfer to offer more complex products, which will require more mature industrial operations; • Possibilities to access new and global markets; • Establishment of a new and more dedicated industrial chain. • Construction of new aerospace production site in São Bernardo do Campo.
- 45. CORPORATE STRATEGY • Keep a low cost unit for composite parts manufacturing and sourcing in the market. • Invest only in critical resources to become a qualified “level 1” manufacturer; • Expand assemblies and integration capacities, in order to offer complete structural segments and major sub-assemblies; • Move into an independent organization.
- 46. PRODUCT MANAGEMENT ORGANIZATION • Under development to support new contracts; • For current businesses, InbraAerospace shares resources with other B.U´s with special concern to keep processes under the requirements of Embraer and certification authorities.
- 47. MANUFACTURING CAPABILITIES • Manufacturing processes follow those requested by the aerospace segment, according to the design of outsourced parts requirements, like carbon fiber, glass fiber, NDT inspection, honeycomb processing, etc.