Engineering Design Capability

EXECUTIVE SUMMARY

Safe Air is a unique one stop service centre primarily set up to service the Royal New Zealand Air Force (RNZAF), and specifically for the Lockheed Martin C-130H Hercules and P-3K2 Orion (airframes, engines and propellers) and SH-2G Seasprite helicopter maintenance. Embodied in the organisation is a highly capable engineering design team rich in experience and expertise on these and other airframe types.

The Safe Air engineering design team draws its experience from its guardianship of the RNZAF’s fleet, as well as ongoing supplementation of Air New Zealand’s commercial aircraft engineering services requirements (having been a fully owned subsidiary of Air New Zealand until July 2015). Safe Air itself has achieved over 1.5 million maintenance hours on Lockheed Martin airframes and various helicopter types, all with the close support of the current engineering design team.

Safe Air’s engineering design expertise and experience includes;

» aircraft structural repair design and approval

» aircraft and component modification development and approval

» structural testing

» tooling and mechanical equipment design

» certification and approval of design data

» 3D data capture

» Documentation Services

Safe Air’s engineering design services are available either as a part of a wider engineering programme or as a discrete service including engineering liaison, consultancy or short term contract engineers. All Safe Air engineers are experienced at operating offsite within a customer’s facility.

Safe Air has the benefit of now being a wholly owned subsidiary of Airbus Helicopters and an integral part of Airbus Group Australia Pacific (AGAP). This substantially increases the total

engineering capability and capacity, which Safe Air is readily able to draw upon to meet the demands of, or provide support to, larger and more complex projects.

Safe Air operates under New Zealand Civil Aviation Authority (NZCAA) Part 146 and CASA Part 21M Design Approvals and holds design delegations from the NZCAA, the RNZAF and previously the Royal Australian Air Force (RAAF).

Through its Supply Chain the company is also able to tap into the resources and expertise of a number of national and international partners with complementary capabilities in manufacturing, component supply and repair services to provide value propositions into global aviation supply chains.

Our combined attributes and capabilities mean we can offer customers the opportunity to benefit from our ‘Kiwi Ingenuity’, our ‘Can Do Attitude’ and our passion for aviation. These make us ideal contenders for those smaller more complex niche projects that are typically too disruptive for larger mainstream aviation designers and manufacturers to consider.

Safe Air can demonstrate, through countless examples, the special focus and commitment to deliver totally compliant high standard results through:

» Well coordinated work-flow planning and supply chain management

» Design engineering expertise to innovate, develop and certify solutions

» A broad depth of manufacturing capability, competency and experience

» High levels of quality and conformance to required standards

» Available capacity to take on short lead-time work

» Flexibility to produce one-off prototyping, and small, medium or larger production runs.

A brief summary of a few notable recent project examples is provided below.

ENGINEERING SERVICES

Aircraft Structural Repair Design and Approval

Safe Air has particular structural experience with mature airframes such as the Lockheed Martin C-130H and P-3 Orion. Our team has developed over 500 repair schemes for a wide variety of commercial and military aircraft. Safe Air has accumulated over 1.5 million maintenance hours on Lockheed Martin airframes, much of which has been directly supported by our onsite engineering design team.

Structural Testing

Design, construction and operation of structural testing equipment to demonstrate compliance with specified loading conditions. Documentation of test plans and results.

Aircraft and Component Modification Development and Approval

Across both military and commercial airframes, the Safe Air engineering team has accumulated a range of modification experience including structural, avionic and aircraft interior. A sample of completed projects includes;

» Lockheed Martin P-3 Orion autopilot

installation

» Kaman SH-2G door jettison mechanism

design and installation

» Commercial aircraft galley equipment design

to manufacture

» C130 usage monitoring equipment installation

» Development of replacement radomes for P-3

Orion aircraft in conjunction with Cobham

Advanced Composites Ltd

» Design of major modifications for Boeing

Business Jet (737)

» Modification and installation of a Flight Data

Acquisition System on B1900 aircraft

» Development of a personnel rappelling device

for RNZAF NH90 helicopters

» Development of a Business Class Seat STC

for Air New Zealand’s 787-900

» Design of repair for RNZAF P-3 Engine

Nacelle Longerons

» Integration of FLIR Safire III to RNZAF P-3

Further details are provided for the four most

recent projects later in this document.

Tooling and Mechanical Equipment Design

The Safe Air engineering team’s experience

extends to the design of unique tooling to meet

specific technical requirements. Recent examples

of completed tooling include;

» Jigs for manufacture of helicopter weapons

pylon

» Rear fuselage removal stand for P-3 Orion

aircraft

» Adaptor for Rolls Royce T56 Mobile Engine

Test Stand (METS) to enable testing of

different engine configurations

Certification and Approval of Design Data

Expert advice and assistance with certification of

products to comply with airworthiness authorities

covering modifications, Type Certificates (TC’s),

Supplemental Type Certificates (STC’s), Parts

Manufacturing Approvals (PMA’s), and Technical

Standards Orders (TSO’s).

Includes development of technical data to meet

certification standards and compiling compliance

documentation. We can also issue Design

Statements of Compliance and Design Approvals

and assist with EASA, CAR 35 (Australia) and

FAA (USA) approvals through our global

engineering design network.

3D Data Capture

The Safe Air team employs advanced laser

tracking equipment to capture and display 3D

coordinates for the following applications:

» Aircraft symmetry and alignment checks

» Jig alignment checks

» Positional and planarity checks

» Mapping data (damage plots on aircraft

surfaces, modelling aircraft interior and

exterior surfaces)

» Reverse engineering

Documentation Services

Safe Air’s engineering service is

complemented by a comprehensive range of

documentation services including;

» Technical data packages

» Engineering drawings, illustrations (2D and

3D)

» Publications created to industry standards

including manual supplements

» Bulletins

» Engineering reports

Other Services

Preparation of aircraft trim charts to FAR

121 requirements

» Take off and landing charts for light

aircraft

» Aircraft weight and balance and

Centre of Gravity calculations

RECENT PROJECTS

NH90 Rappelling Device

OBJECTIVE

To produce a simple, reliable, robust and safe design that meets the requirements of the RNZAF.

Used for rapid troop deployment and training activities out of the NH90 Aircraft, similar to those currently undertaken using the RNZAF’s UH-1H Iroquois aircraft.

CAPABILITY

Max 8 Troopers in two groups of 4 in quick succession

Ropes are released after deployment

Rope release under load if necessary (emergency)

Troop extraction

Maximum weight for each person using the device (including their kit and equipment) is 180 kg

Max load of 2160 kg

(Includes Factor of Safety x 1.5 + Dynamic Factor x 2)

APPLICATIONS

This design can be modified to suit a much wider range of aircraft than just the NH90.

DESIGN FEATURES

Designed in conjunction with the RNZAF to suit their specific requirements

No modification to the aircraft required

Safety locks to avoid inadvertent release

Fabricated from lightweight welded aluminium box section

Optimized for structural efficiency & manufacturing simplicity

Transfers loads to the airframe

Can be easily and quickly installed by two people using quick release pins. No tools required to remove device

Mounted high into the roof of the cabin

Sturdy mechanical release mechanism

Simultaneous rope release

Single operation from the front or rear of device

Meets the applicable FAR 29 requirements

787-900 Business Class Seat STC

PROJECT INVOLVED:

- Successful collaboration with CAA NZ, Boeing, 3rd Party subcontracted design services & AIR NZ.

- Developing comprehensive Certification Plan to manage compliance to regulatory requirements & ensuring subsequent A/C on-time-delivery.

- Establish ELOS to certain regulatory rqmts acceptable to CAA NZ when certifying seat/bed actuation.

- Successful issuance of CAA NZ STC to Air NZ.

1. Regulatory

“Knowledge of requirements of the relevant aviation authorities”

2. Seats

“Safety levels established for authorising functionality”

3. Bed

“Understanding of end user and customer requirements and expectations”

4. Aircraft

“Liaison with customer from concept through to the installed product is fully functional”

P-3 FLIR Safire III Integration

OBJECTIVE

Design, integrate, validate and certify the installation of a stand alone FLIR EOIR Turret to a P3 Orioin

PROJECT INVOLVED

Structural design for component mounting

Electrical design for integration to aircraft and surveillance suite systems.

Radome modification

Aircraft modification and component installation

Installation testing / Acceptance testing

Tailored Certification & Approval

ENGINEERING DESIGN SERVICES

Structural testing

Aircraft repair design

Modification design

Documentation management

Certification & approval

Design to manufacture

3D CAD Modeling

Finite Element Analysis

LASER Tracking for highly accurate real time positional data

Recent modification of P3 with FLIR Mount.Recent modification of P3 with FLIR Mount.

P-3 Engine Nacelle Longeron Repair

OBJECTIVE

Determine a solution for cracking damage on RNZAF P-3K2 Orion Engine Nacelle Upper Longerons.

PROJECT INVOLVED

Design and substantiation of repairs to extensive cracking damage on the P-3 Engine Nacelle Upper Longerons.

Design of Longeron tooling to aid the removal & installation of replacement Longerongs during an aircraft servicing.

Organizing manufacture of the tool to meet stiffness and tolerance requirements.

Personnel Overviews

Refer table in Annex on following page showing a summary of experience of the senior engineering team.

Key Contact

David Goodwin

Engineering Design Manager

P: +64 3 572 7840

Mb: +64 21 221 3928

Fx: +64 3 572 7655

Email: david.goodwin@safeair.co.nz

PO Box 244

Blenheim

Marlborough 7240

New Zealand

Senior Engineering staff – Experience Summary

Name

Position

Basic

qualification

Delegations /

Authorizations

Previous Employment (years)

Strengths

Total

NZ/Intl OEM’s

Airline

support Other SAL

David Goodwin

ED Manager

CAANZ, CASA (AUS) and

RNZAF.

Previously held delegation from

DGTA (AUS)

13/10 Honeywell

Raytheon

Hawker Pacific

Beechcraft

6

Air NZ

Qantas

Design Engineer

– Hawker Pacific

5 » Team leadership

» Strategy development

» Operational oversight of the RNZAF Beech T6 program

» CAA senior person oversight of all design work

» engineering procedures, scheduling, finances, business

development and marketing, project management, tender

preparation, quoting, management liaison, mentoring and

development of Design Engineering and Ohakea staff

» Avionics related documents, design, review or approval for

both rotary and fixed wing aircraft

Damian Scott

Senior Design

Engineer

B.Eng Hons (Aero

Eng)

HNC (Mech Eng)

Safe Air , CAANZ , RNZAF

Air NZ. Previously BAE

Systems.

13/12 12 10 BAE Systems –

Airframe

Technology 1990-

2002

13 » Aircraft Structures, modifications / repairs, FEA

» Holds a SOC authorisation within ANZTO & RNZAF

approval delegation.

» Considerable experience of airline repair design.

» Specialist design of Role and Ground Support Equipment

Matthew Potts

BE Hons (Mech),

MEM

CAANZ , RNZAF

Air NZ, Altitude

16/1.5 1.25 L3-IS

0.25 Boeing

2 16 » Structures, modifications / repairs.

» Hold SOC approval with Air New Zealand Technical

Operations and Altitude Design.

Cameron

Ready

NZCE (Mech) RNZAF

Safe Air

18/1 -- --- --- 11 » Structures, mods/repairs.

» Specialise in Design for manufacture

» Experienced in Ground Support Equipment Design

» Extensive experience in 2D & 3D CAD design & Drafting.

» Management of customer technical design data

requirements during a/c heavy maintenance and mod work.

(MoD LEP Upgrade etc…….)

Senior Engineering staff – Experience Summary

David Goodwin (ED Manager)

David is a senior manager at Safe Air Ltd, with primary responsibilities as part of the leadership team; to develop strategy that both supports core business and promotes efficient and profitable growth. Keys to this are the management and development of the design engineering business unit and the operational oversight of the RNZAF Beech T6 program at Ohakea. As a CAA senior person David is responsible for oversight of all design, certification and test related activities for the company. He is responsible for engineering procedures, scheduling, finances, business development and marketing, project management, tender preparation, quoting, liaison with other managers and mentoring and development of Design Engineering and Ohakea staff. As a qualified engineer he is also responsible as the Chief Design Engineer for allocation of design delegation, review and approval of design data, preparation of test schedules, system safety analysis, failure mode and effect analysis, modification orders and instructions, technical assessment and design certification.

David holds delegation from NZCAA, CASA(AUS) and RNZAF. Having also previously held delegation from DGTA (AUS).

Previously David as Principle Design Engineer – Hawker Pacific David was responsible for avionics related documents, design, review or approval for both rotary and fixed wing aircraft for a variety of roles. He was responsible for mentoring and overseeing of the work and development of Graduate Design Engineers and Technical Officers.

He was Business Improvement Team member, responsible for the steering of the department with respect to adherence to regulations and approved guidance material, safety, configuration control, document management processes, procedures, business planning and recruiting. Project example include:

Project 1: Engineering and certification management of a bespoke, single ship, multi-role aircraft for use by the Malaysian Government for aerial mapping,

medivac and corporate transport. Very closely liaised with Malaysian DCA to acheive transfer from Australian civil register to the Malaysian civil register in

Australia prior to ferry flight.

Project 2: Full scope and engineering management of a full mission system integration to a King Air 350 for Malaysian Police. The final mission capable platform included; EO/IR, SAR Radar, COFDM secure Video Streaming, SatCOM, Drop Hole, Video Management system and jump seat.

Project 3: Application of 6Sigma principles and engineering experience to develop new design procedures for Safe Air engineering including a new document management system, new templates, new job induction and closure procedure, new numbering system and all applicable training and associated quality requirements with the production ‘go live’.

Senior Engineering staff – Experience Summary

Damian Scott

University of Manchester, England. Bachelor of Engineering (BEng) Honours.

Safe Air. Senior Design Engineer responsible of design changes (repairs and modifications) to aircraft structures, mechanical systems and components, including check and approval. Design of specialist Role Equipment and Ground Support Equipment and for use with aeronautical products, aircraft structures design and analysis, aircraft interiors design and development, Finite Element Analysis (FEA), computer aided design and liaison engineering.

BAE Systems (formerly British Aerospace (BAe) including 5 year sponsored Engineering Undergraduate Training Program. Graduate engineer, stress engineer/ structures engineer, Senior Structures Engineer. Experience included aircraft structures, in-service aircraft support, aircraft return to works and development, aircraft type record and fatigue type record development, fatigue check stress, structural analysis (FEA), structural test support, Aerodynamics support, design/drafting

Delegations and Authorities – Safe Air Limited authorized to check design change documentation, manual amendments, drawings, interim responses, test schedules (airworthiness and functional), reports, publication amendments and specifications/proposals. Authorized to approve design certificates, statements of compliance, design change documentation, manual amendments, drawing, validation of design software, approved technical information incorporation, interim response.

Civil Aviation Authority of New Zealand (CAANZ) authorized to approve aircraft modifications and repair i.a.w. Civil Aviation Rule 21.81 and Rule 21.433. Delegation may only be exercised in respect of work performed by Safe Air Limited under Design Organization Certificate Number DO12884. Delegation may be exercised for modifications and repairs to aircraft that are classified as Class B design changes as defined in Civil Aviation Rule Part 146.

Royal New Zealand Air Force (RNZAF) Delegated Engineering Authority (DEA) for Grade A Airframe and Grade B Mechanical Systems, Components and equipment including authorising; publication amendments, new drawings and drawing amendments, RNZAF concessions, New Zealand repair schemes, special local manufacture, and process deviations.

Air New Zealand letters of authorization to; check ANZES Technical Instructions and Technical Assessments, sign a Statement of Compliance (SOC) for aircraft design changes, and accept Technical Data on behalf of the Operator (Data Acceptance, CAANZ Part 119 activity).

Previously BAE Systems authorized to sign for checked; Technical Reports, Drawings (Stress), Stress and Fatigue calculations/reports, Fortran Programs, FEA and Accredited Structural Analyst (FEA).

Senior Engineering staff – Experience Summary

Matthew Potts

University of Canterbury ME in Management & BE Mech (Hons).

ANZES SOC, RNZAF DEA, Altitude SOC Approval

Safe Air. Two years production improvement projects for propeller overhaul facility. Prepared tenders for airframe and engine maintenance work. Fourteen

years designing repairs and modifications for aircraft structures and components, covering a wide range of aircraft types. Design of P3 METS adaptor.

Secondments:

Kaman Aerospace International Support Centre – KAISC (Nowra, Australia) Three months supporting the RAN Seasprite helicopters, defect

investigations, publication amendments, and potential structural modifications

Air New Zealand. Many secondments to Air New Zealand Liaison Engineering Group.

L-3/IS Communications (Texas) One year seconded for the RNZAF P-3K Systems Upgrade Project (SUP). Installation design Engineer for new systems. Conceptual design of tactical stations, weight and balance, & review of structural drawings.

Boeing Commercial Aircraft (Seattle) Three months designing & substantiating fuselage primary structure repair schemes for Boeing 737-series worldwide operators. Static strength and fatigue analysis using Boeing design tools.

Air New Zealand Engineering Services (Christchurch) - Project Engineer One year Evaluating & reviewing of tooling and test equipment for Boeing aircraft. Production and coordination of equipment manufacture. Technical validations for non OEM tooling.

Senior Engineering staff – Experience Summary

Cameron Ready

Secondments:

Air New Zealand Technical Operations, Auckland (February-August 2014 – B787-9 STC (Business Premiere Seat/bed re-activation).

Altitude Aerospace interiors (CHCH): Multiple secondments to support 2D & 3D CAD design and Drafting for projects:

- B737-8 BBJ A/C fitouts

- FAR23 A/C Cockpit Security Barrier

- A/C end of lease reconfigurations (B747)