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AerostructuresNovember 1, 2017 Vol. 27, No. 36

Foley delivers milestone 100th integrated propulsion system to Airbus Final Assembly Line in MobileWhat a difference 100 units make.

When Airbus visited the Foley facility in the first quarter of 2015 to review the site’s plans to integrate V2500 and CFM56 engines with their nacelle systems for the nearby A320 Final Assembly Line in Mobile, the customer was apprehensive.

“They had some concerns with our ability to make the first delivery,” said Foley A320ceo Program Chief Derek Eberly at the time.

100 integrated propulsion system deliveries later, those initial fears have been alleviated.

“Airbus has been pleased with the progress the Foley facility has shown since the first delivery,” according to Chula Vista V2500 Value Stream Business Manager Leslie Thurman.

She was speaking in the aftermath of Foley’s delivery of its 100th integrated propulsion system to the Airbus FAL on Oct. 25.

From two units a month to eightSince delivering the first V2500 integrated propulsion system on Jan. 20 of last year – for installation on a JetBlue A321 – the Foley facility has added CFM56 engines, as well as V2500 engines for the Embraer KC-390 military transport, to its integration portfolio. (Continued)

The Foley facility delivered its 100th A320ceo podded propulsion system – a nacelle system integrated with an engine – to the Airbus Final Assembly Line in nearby Mobile on Oct. 25. The milestone unit will be installed on a Delta Air Lines Airbus A321.

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Meanwhile, delivery of finished units has ramped up from an initial pace of two a month to eight.

Of the 100 integrated propulsion systems that have now been delivered, 72 have been of the V2500 variety and 28 have featured the CFM56 engine. The Foley facility also recently completed two V2500/KC-390 integrated propulsion systems, which have yet to be delivered.

The Foley site is expected to deliver its first Airbus A320neo integrated propulsion system in January 2018.

UTC Chairman Greg Hayes comments on future of A320neo nacelle, Airbus acquisition of Bombardier C Series program during earnings call with analystsHow will the Airbus decision to offer a different nacelle for the Airbus A320neo impact UTC Aerospace Systems?

UTC Chairman and CEO Greg Hayes responded to this question during UTC’s 2017 Third Quarter Earnings Conference Call with financial analysts on Oct. 24.

“We’ll continue to offer our nacelle to the customers through the life of the program, as is our right under the contract,” said Hayes. “And we think… we have a great nacelle. We’ve got what we think to be a competitive one from a cost standpoint and we’ll unfortunately be competing with our customer in the offering of that nacelle in the late 2020s.”

He continued: “But I’ve got to believe that (for) the customers, once they have the Pratt & Whitney GTF engine with the UTAS nacelle, switching costs will be somewhat significant. So I think the prospects of us losing that business completely are pretty low. But we’ll keep working with Airbus. And I think we’ve seen this play before where the aircraft manufacturers decide to in-source, and then, after a while, they recognize that some things they can do really well and some things not as well as some of their suppliers. So we’ll keep working with Airbus and we’re going to keep our focus on delivering the best quality nacelle to our customers.”

Here a few other highlights from Hayes’ remarks during the earnings conference call…

On the Airbus acquisition of the Bombardier C Series program: “In my mind, it was a validation of the Geared Turbofan because the GTF… is the sole-source engine on the C Series. And despite all that’s been written about the durability issues… the fact is the engine works and Airbus has high confidence in it or they wouldn’t have done this deal. And so to me, it was really just validation that the GTF works.”

On UTC Aerospace Systems’ strategy for addressing continuing pressure from airframe manufacturers to lower prices: “The focus from the OEMs to reduce cost is never ever ending. And the fact is, we recognize we have to continue to take cost out of our product if we want to be competitive, and we’ve told both Boeing and Airbus we’ll continue to work with them to find ways to do that across all of the portfolio. But this is not going to end. And if you think about it, the whole premise behind the Rockwell Collins acquisition is to find ways to be more innovative on the airframe, to take weight out, to take cost out and to offer innovative solutions to the airframers. And the scale that they bring to us gives us the opportunity to do things that we couldn’t do on our own. And I think that’s what you have to focus on with the Rockwell Collins (acquisi-tion)… there is a huge value proposition to our customers with this acquisition.”

On what’s going to drive the next generation of airframe decisions: “It’s going to be about connected aircraft. It’s going to be about communications systems. It’s going to be about the ability to take digital across all of the systems on the airframe. And that’s one of the benefits to us… we’ve got all of these systems that we can now connect and that we can do diagnostics on that can really differentiate our offering and add real value to both the OEMs as well as to the airlines by providing real-time data, real-time diagnostics, real-time spare parts availability.”

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“We’ve been doing very well against aggressive 2020 goals”Chula Vista site’s growing progress in conserving energy and water, eliminating waste is shrinking its environmental footprint“Think globally, act locally” has long been a rallying cry for environmen-talists, urging people to consider the health of the whole planet while taking steps to improve the environment in their own cities, communities and neighborhoods.

The phrase also sums up the UTC approach to environmental steward-ship. As a company with operations around the world, UTC has to think globally… and it has set aggressive environmental goals for each of its local sites to meet by 2020, as well. As the calendar year draws to a close, Aerostructures’ headquarters site in Chula Vista is well positioned to meet its interim 2017 goals in multiple areas.

Set against a 2015 baseline, the 2020 goals are:

o Water usage: reduce by 25% o Greenhouse gasses: reduce by 15%o Hazardous waste: reduce to 10% of total wasteo Recycling of waste: increase to 90%

“We’ve been doing very well against all these goals, but we can’t take our foot off the pedal,” said Chula Vista EH&S Manager Rick Siordia. “Why? In any area where we meet or exceed the goal, the central EH&S team recalibrates and gives us a new goal. It’s environmental continuous improvement.”

Here are capsule summaries of where the Chula Vista site stands today in reaching each of the 2020 goals… as well as its progress in hitting the interim 2017 goals essential to getting there:

Water Usage

2015 baseline: 40.8 million gallons2017 goal: 35.3 million gallons2020 goal: Reduce by 25% to 30.6 million gallons

“We’re doing well on the goal to get to 35.3 million gallons by the end 2017,” said Siordia. “We’re currently at about 24.1 million gallons with two reporting months left. I’m certain that we’re not only going to reach, but exceed that goal.”

Siordia credits a number of factors that will help the site exceed its annual goal. They include increasing the amount of water recycling at the waste treatment plant, as well as implementing changes to the chemical processing lines and best management practices on the cooling towers that use chilled water to lower the temperature of the engines at the site’s electric co-generation plant. (Last year, water softening tanks were added for each tower, slowing the chemical buildup. That meant the same water could be used for a longer period of time before the tanks were flushed and refilled. That change was expected to reduce water usage by 1.5 million gallons a year.)

“Think globally, act locally.”

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“This is another area where I feel confident that we’ll do well because our emissions goal is to get to 17,700 metric tons this year and we’re currently at about 13.600 year-to-date,” said Siordia. “Of course, exceeding a goal means that the central team will come back with a new challenge for 2018. The better the Chula Vista facility does, the more it helps UTAS meet the company’s overall 2020 goals.”

Contributing factors behind the 2017 greenhouse gas reduction progress include the shuttering of Building 99 and parts of Building 29, as well as the retirement of a chemical processing tank that required natural gas heating 24/7. On the electrical side, Building 61 and the Building 55 area being used by the A350 XWB program were both retrofitted with LED lighting (which is up to 80% more efficient than traditional lighting).

“And we’ll continue to ask people to shut down lights, machinery, computer monitors and other equipment at the end of the day. Our ‘Shut It Down’ program is something all employees can participate in to make a big impact on reducing greenhouse gases,” said Siordia.

Hazardous Waste

2015 baseline: 2.5 million pounds2017 goal: 2.4 million pounds2020 goal: 2.2 million pounds

“We’re close to the 2017 goal, but this is one of our toughest challenges,” said Siordia. “Even with some production slowing down, we’re at 1.9 million pounds with two months to go. With everyone’s support and good management of the waste, we’re expecting to finish out the year right on target to meet this year’s goal. We’re watching this one very closely.”

Waste Recycling

2015 baseline: 20% waste recycling2017 goal: 95% waste recycling2020 goal: 90% waste recycling

“The baseline was set at 20%, but we achieved a 95% waste recycling rate in 2016,” said Siordia. “UTAS did not want any backsliding, so our 2017 goal was set at 95%… even though that’s less than the 2020 goal requires.”

He added: “We’re very proud of our progress in this area because we’re already recycling 95 percent of our waste. With that said, there are probably still more opportunities out there that need to be researched.”

Greenhouse Gases

2015 baseline: 19,911 metric tons2017 goal: 17,721 metric tons2020 goal: Reduce by 15% to 16,924 metric tons

“We’ll continue to ask people to shut down

lights, machinery, computer monitors

and other equipment at the end of the day.

Our ‘Shut It Down’ program is something

all employees can participate in to make

a big impact on reducing greenhouse

gases.”

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Prestwick apprentices step out of their comfort zones twice to make a difference in their community Working with exotic alloys and carbon fiber to repair highly complex nacelle components calls for a very specific skills set. Constructing a wooden classroom from the ground up for students aged 5 to 12, in contrast, requires entirely different expertise. But that didn’t prevent five Prestwick Service Center (PSC) apprentices from taking on the challenge… the Ayrshire Modern Apprenticeship Challenge, to be specific.

The annual event is sponsored by Skills Development Scotland, a government body focused on improving youth education and training to better meet the needs of industry. During the March-through-August activity, appren-tices in fields ranging from agriculture to hairdressing to engineering – and many other disciplines – are tasked with planning and completing a project that benefits their local community.

“We’ve participated since the Challenge’s inception in 2004,” according to PSC Training Officer Robert Paterson. “It’s quite a stretch for our apprentices, given the specialized work they do at our facility. It’s far easier for apprentices at other organizations that are focused on becoming electricians, plumbers, etc.”

PSC apprentice Ryan White agreed.

Six weeks of persistence paid off“After speaking with teachers, pupils and parents from the local Elderbank Primary School about what they might need or want, we decided to design and construct an outdoor classroom,” said Ryan. “The planning and construction of this project definitely pushed us out of our comfort zone. We had to learn new skills, such as basic groundwork and also how to erect a wooden frame and roof using woodworking tools. This is nothing like what we do working in the aerospace industry!”

But six weeks of persistence paid off with a handsome new learning environment that will be used for everything from art activities and poetry exercises to working on mathematical literacy and nature watching.

Constructing the classroom was not the only time the PSC appren-tices had to step out of their comfort zones to complete the Challenge.

This team of Prestwick Service Center apprentices was recognized by a panel of judges for delivering the best presentation during the recent Ayrshire Modern Apprenticeship Community Challenge. The annual event tasks apprentices from various industries with planning and completing projects that benefit their local communities. Pictured above with their prize are (from left to right): Lewis Addison; Lee Ferguson; Ryan White; and Ross Chapman (not pictured is Dylan Goldie).

“The planning and construction of this project definitely

pushed us out of our comfort zone. This is nothing like what we

do working in the aerospace industry!”

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“Not letting inexperience get the better of us”“The main focus of the challenge is the charitable aspect, but there’s also an element of competition, too,” said Paterson. “For example, the apprentices vie for a ‘Best Presentation Award’ – they’re required to deliver a presentation to an audience of local dignitaries, the other apprentice teams and benefactors, and also a judging panel detailing how they approached and executed their project. Awards are also presented for the most innova-tive project and the biggest ‘journey’ – how much apprentices learned and grew as a result of completing their project. Finally, there’s an overall winner that’s judged on a combination of innovation, creativity, effect on the benefactor, quality of portfolio, and standard of presentation.”

After all of the apprentice teams had detailed their projects in front of the judges, the PSC team walked away with the Best Presentation Award… but it wasn’t easy.

“None of us involved in the presentation actually had any public speaking experience, so we were all a bit nervous,” explained Ryan. “But with a good solid PowerPoint and plenty of practice, we managed to

succeed and take home the award. The biggest chal-lenge was not letting inexperience get the better of us. Fortunately, we had attended a presentation skills workshop beforehand to help us with our delivery of the information and controlling the nerves.”

In addition to Ryan, the other members of the award-winning PSC Modern Apprenticeship Challenge team included:

n Lewis Addisonn Ross Chapmann Lee Fergusonn Dylan Goldie

A team made up of Prestwick Service Center apprentices constructed this outdoor classroom at Elderbank Primary School as part of the Ayrshire Modern Apprenticeship Community Challenge. The event offers local businesses the opportunity to showcase the benefits apprentices bring to the local community. The new learning environ-ment will be used by students aged 5 to 12 for everything from art activities and poetry exercises to working on mathematical literacy and nature watching.

“None of us involved in the presentation actually had any

public speaking experience, so we were all a bit nervous.”

What’s a Modern Apprentice?n The Modern Apprenticeship Program is a

structured training program designed to develop students between the ages of 16 and 21 into skilled, qualified, tradespeople. There are Modern Apprentices in practically every industry sector: engineering, agriculture, EH&S, hairdressing, IT, finance, etc.

n The engineering apprenticeship is the most structured and controlled, with participants earning a Scottish Vocational Qualification (Level 2) and a National Certificate in Aeronautical Engineering during the first year (which is spent mostly off the job at a local engineering college). After that, the appren-tices come on site to the workplace permanently and work towards a Scottish Vocational Qualification at Level 3 and a Higher National Certificate (HNC) in Aeronautical Engineering during years two and three. The HNC and Level 3 qualifications are considered as entry level to going to a university to complete a full degree.

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“I think we can make a difference for our children”Mexicali employees plant trees – and hope for a greener future – with the aid of a UTAS Mini GrantWhat do you get when you combine Mexicali’s hot dry climate, growing population, unpaved roads and agricul-tural field burning? The most polluted air among Mexico’s large cities.

Mexicali Design Center Engineer Francisco Burciaga is determined to do something about it, however. And he took a positive step in that direction on Oct. 21.

Aided by a UTAS Green Initiative Mini Grant, Francisco and some fellow employees – along with a group of citizens committed to improving quality of life in the city – planted 200 trees at a local park where people go daily to practice sports.

“Planting a tree directly benefits us all,” he said. “Trees and plants absorb carbon dioxide, improving air quality. They also help moderate temperatures by creating a cooling effect which can counteract the heating effect of pavement and buildings. Additionally, they bring natural elements and wildlife to the urban environment. In short, they increase the quality of life for residents within the community.”

The Mexicali volunteers, in partnership with the Todos Somos Mexicali citizens group, planted a combination of Mesquite and other drought- and heat-tolerant trees and bushes at the Ciudad Deportiva sports complex.

With a financial boost from a UTAS Green Initiative Mini Grant, a group of Mexicali employees – along with these volunteers from Todos Somos Mexicali, a group of citizens committed to improving quality of life in the city – planted 200 trees at a local park on a recent weekend. Planting new trees can help to reduce the amount of carbon dioxide in the air, which is a major contributor to global warming and climate change. Mexicali has the most polluted air among Mexico’s large cities.

“Planting a tree directly benefits us all.”

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“I think what we did will motivate the community to come out and play at the park,” Francisco said. “It was wonderful to see young community volunteers and Mexicali employees working together to create a green place for the future.”

He added: “It’s important to create a culture of reforesting and caring for our trees and other natural resources. It’s very rewarding to participate in a project designed to help build a greener world. I think we can make a difference for our children.”

“It was wonderful to see young community volunteers and Mexicali employees working together to create a green place for the future.”

Looking for the Aerostructures home page on the web? Seeking a back issue of Skylines? We can hook you up!If you’re not sure where to find the Aerostructures home page on the intranet, you can follow these three steps from the UTAS home page.

n Hover your cursor over the Organization pull-down menu at the upper left.

n Find the “Aerostructures” link under the Strategic Business Units heading.

n Click on Aerostructures.

You might be asked to enter your password to access the site.

You can also access the Aerostructures home page by clicking here.

Once on the Aerostructures home page, you can get to back issues of Skylines and Dialogue – the monthly e-news-letter for leaders – by going to the News pull-down menu. Skylines issues are organized by year. An index of articles in each edition, organized by date and topic, will be added within the next several weeks.

If you’re looking for a specific article that pre-dates the archive, please contact Skylines editor Jeff Hulewicz at extension 3635 or at: jeff.hulewicz@utas.utc.com.

In addition to Skylines, you can also access a lot of other helpful information on the Aerostructures home page.

n Wondering what the paid holiday dates are for Christmas and New Year’s? Click on Need to Find and then “2017 Company Calendar.”

n Want to find out more about Aerostructures’ various Employee Resource Groups? Click on Employee Toolbox and scroll down to the group of your choice.

n Need to contact a colleague at another UTAS site? You can instantly see the current local time at that location on the world clock.