PowerPoint_files/Chromalloy Group Ltdx 2010 Symposium

PWCS Symposium 2010
August 2010
Content
Chromalloy
Organization Chart
Chromalloy capabilities
PWC Divisional Support
Chromalloy U.K
Chromalloy France
Chromalloy Dallas
OpEx and Turnaround time Focus
August 2010 | Moving Our Industry Forward | Company Confidential
Page 2
The Carlyle Group
• The Carlyle Group is one of the world’s
largest private equity firms with $91.5
billion in capital committed to 66 private
equity funds worldwide.
• Carlyle has been the leading investor in
the aerospace, defense and IT /
government services sectors .
• Carlyle’s goal is to build the long-term
value of Sequa and its holding
companies through synergies, process
improvement and investment.
Backed by one of the largest private equity banks in the world
August 2010 | Moving Our Industry Forward | Company Confidential
Page 3
Sequa Corporation
~ $1.5B / 5,000 employees world wide
August 2010 | Moving Our Industry Forward | Company Confidential
Page 4
Chromalloy History
• Started as a Chromalloy American Corporation in the late 1950s
• The first company to leverage protective coatings on Turbine Airfoils
• Developed repair technologies as an extension to OEM designs
• DER repairs began in 1991
• PMA started in 2000
• Acquired by The Carlyle Group in December 2007
• Significant expansion in casting capability in Tampa 2009 / 10
> 50 years of leadership in gas turbine repair technology
August 2010 | Moving Our Industry Forward | Company Confidential
Page 5
Footprint
Burlington, MA
Carson City, NV
Orangeburg, NY
Midwest City, OK
Dallas, TX
San Antonio, TX
Vancouver, Canada
Victoria, Australia
Perth, Australia
Beijing, China
Dubai, UAE
Burlington, MA
Carson City, NV
Orangeburg, NY
Midwest City, OK
Dallas, TX
San Antonio, TX
Vancouver, Canada
Victoria, Australia
Perth, Australia
Beijing, China
Dubai, UAE
Rochefort, France
Saint Ouen, France
Mumbai, India
Cengkareng, Indonesia
Qiryat-Gat, Israel
Kuala Lumpur, Malaysia
Tilburg, Netherlands
Jeddah, Saudi Arabia
Lamlukka, Thailand
Nottingham, UK
Glasgow, UK
4,000 employees in 14 countries around the world
August 2010 | Moving Our Industry Forward | Company Confidential
Page 6
Content
Chromalloy
Organization Chart
Chromalloy capabilities
PWC Divisional Support
Chromalloy U.K
Chromalloy France
Chromalloy Dallas
OpEx and Turnaround time Focus
August 2010 | Moving Our Industry Forward | Company Confidential
Page 7
Organization
A. F. Lauzon, Jr.
President
T. van der Linden
VP Sales
P. Howard
VP Technology &
Quality Assurance
M. Beffel
VP Operations
A. Farrant
VP Marketing &
Corp. Comm
M. Held
VP Finance
J. Bollman
VP HR
Pete Watson
VP IGT
D. Albert
VP External Affairs
Dedicated, focused and proven leadership
August 2010 | Moving Our Industry Forward | Company Confidential
Page 8
Organization Chart – Small Engine Group
August 2010 | Moving Our Industry Forward | Company Confidential
Page 9
Content
Chromalloy
Organization Chart
Chromalloy capabilities
PWC Divisional Support
Chromalloy U.K
Chromalloy France
Chromalloy Dallas
OpEx and Turnaround time Focus
August 2010 | Moving Our Industry Forward | Company Confidential
Page 10
Product / Service Offering
Coatings
Chromalloy is the world’s
largest provider of EBPVD
coatings
Repairs
High technology, patented
and proprietary processes
define Chromalloy’s repair
capability
Parts
Chromalloy is the only
cradle to grave “hotsection” PMA provider in
the industry
Chromalloy is the world’s largest independent supplier of technologically advanced repairs,
coatings and replacement parts for turbine airfoils and other critical engine components
August 2010 | Moving Our Industry Forward | Company Confidential
Page 11
Coatings
Aluminides
Chromalloy provides advanced
vapor aluminide coating services to
the all the major OEM’s
Overlays
The single largest provider of Low
Pressure Plasma Spray Overlay
coatings for Turbine Applications
Thermal Barriers
Chromalloy has invested over $75M
in Electron Beam Physical Vapor
Deposition
The world’s largest provider of EBPVD coatings
August 2010 | Moving Our Industry Forward | Company Confidential
Page 12
Repairs
Blades
Casting
Cases
Advanced blade tip weld
repairs using Chromalloy”s
patented laser powder welding
techniques
Chromalloy’s advanced Airfoil
Replacement (AFR) repairs for
100% yield programs
LPT Case Flange Replacement
Repairs
Patented and proprietary processes define Chromalloy’s repair capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 13
Markets Served
Commercial
Military
Marine & IGT
• We provide cost
attractive high quality
maintenance solutions
• We provide repair services
on TF39, F108 and other
engines under contract
• We provide cost attractive
high quality maintenance
solutions
• All major airlines in the
world
• USAF and other air forces
• Aero-derivative engine end
users, depots and HIT users,
Navy
• 10% of current business
• 30% of current business
Very secure position in commercial aviation
Growth opportunities in Military and Marine & IGT
August 2010 | Moving Our Industry Forward | Company Confidential
Page 14
Small Commercial Engines Support
GE
CF34 ( COK , CHOL , CSD, CFR)
CF700 ( COK)
T700 ( COK)
CT7 ( COK , CUK)
PWC
PW100 ( CFR , CUK )
PT6 ( CFR , CDAL)
PW200 ( CFR , CUK)
PW901 ( CFR , CUK )
JT15D ( CFR )
Honeywell
TPE 331 ( CAZ)
TFE 731 ( CAZ)
LTS 101 ( CAZ)
Patented and proprietary processes define Chromalloy’s repair capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 15
Content
Chromalloy
Organization Chart
Chromalloy capabilities
PWC Divisional Support
Chromalloy U.K
Chromalloy France
Chromalloy Dallas
OpEx and Turnaround time Focus
August 2010 | Moving Our Industry Forward | Company Confidential
Page 16
PW100 capabilities
PW100, Low Pressure Turbine Housing
Weld Repair of Rear Flange/Sheet Metal
Ring.
Replacement of Rear Flange/Sheet Metal
Ring.
Replacement of Front Sealing Lip.
August 2010 | Moving Our Industry Forward | Company Confidential
Page 17
PW100 capabilities
PW100, Turbine Interstage Case
High Temperature Braze Repair.
Replacement of Outer Bolting Flange Replacement.
Weld Repair of Through-Going Cracks Adjacent to
T6/TT Bores.
Low Temperature Braze Repair.
August 2010 | Moving Our Industry Forward | Company Confidential
Page 18
PW100 capabilities
PW100, Power Turbine 2nd Stage
Replacement of 3rd/4th Blade Paths.
Braze Repair.
Restoration of T7 by Welding.
Restoration of Sealing Groove by Welding.
Restoration of T4 by Ring Installation.
August 2010 | Moving Our Industry Forward | Company Confidential
Page 19
PW100 capabilities
PW100, Turbine Support Case
Replacement of T6/TT Boss by EBW.
Repair of Cracks Adjacent to T6/TT
Bosses.
Replacement of Front Section.
August 2010 | Moving Our Industry Forward | Company Confidential
Page 20
PW100 capabilities
PW100, Turbine Exhaust duct
REP 1
- Remove Surface Damage / Cracks
REP 2
- Plasma Coat Diameter “B”
REP 3
- Plasma Coat Face “A”
REP 4
- Plasma Coat Front Face
REP 5
- Weld Repairs of L / T Edges
REP 6
- Weld Repair Cracks Blanking Area
REP 7
- Weld Repair Cracks Fillet Radius
1725090-SRR-01– Rear Bolting Flange EBW Crack Repair
August 2010 | Moving Our Industry Forward | Company Confidential
Page 21
PW100 capabilities
PW100, 2nd Stage Power Turbine Blade
Restoration of Outer Shroud, Concave and
Convex, Interlock Pressure Faces, by
TIG welding.
August 2010 | Moving Our Industry Forward | Company Confidential
Page 22
Content
Chromalloy
Organization Chart
Chromalloy capabilities
PWC Divisional Support
Chromalloy U.K
Chromalloy France
Chromalloy Dallas
OpEx and Turnaround time Focus
August 2010 | Moving Our Industry Forward | Company Confidential
Page 23
PW100 capabilities
HP Vane Seg
LP Vane Ring
Interstage Case
PT Vane Ring
Chromalloy is specialized for the repair and development of
Nickel based vane ring repair for PWC components :
All vane rings, segments & combustion liners from all PW100
engines turbine sections can be repair by Chromalloy
Chromalloy Small Engine Capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 24
PT6 High-Mid Power capabilities
CT Vane Ring
CT Vane Ring
PT Vane Ring
Interstage
Chromalloy is specialized for the repair and development of
Nickel based vane ring repair for PWC components :
All vane rings, segments & combustion liners from all PW100
engines turbine sections can be repair by Chromalloy
Chromalloy Small Engine Capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 25
PW200 capabilities
CT Vane Ring
PT Vane Ring
Chromalloy is specialized for the repair and development of
Nickel based vane ring repair for PWC components :
All vane rings, segments & combustion liners from all PW100
engines turbine sections can be repair by Chromalloy
Chromalloy Small Engine Capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 26
PW901 & JT15D capabilities
SMED JT15D
HT Stators
PT Vane Ring
Chromalloy is specialized for the repair and development of
Nickel based vane ring & combustion liners repair for PWC
components :
APU 901 & JT15D
Chromalloy Small Engine Capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 27
Combustion Liners capabilities
CC Inner Liner, CC Outer Liner for PW100, PW901, PT6
Chromalloy is specialized for the repair and
development of Liners repair
Chromalloy Combustor Chamber Capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 28
Knife Edge repair capabilities
PW100, PT6 seals Knife Edge repair
Cladding laser
Machining Chromalloy is
newly approved
on knife edge
repair with
cladding laser
deposit
Chromalloy Seals Capabilities
August 2010 | Moving Our Industry Forward | Company Confidential
Page 29
Content
Chromalloy
Organization Chart
Chromalloy capabilities
PWC Divisional Support
Chromalloy U.K
Chromalloy France
Chromalloy Dallas
OpEx and Turnaround time Focus
August 2010 | Moving Our Industry Forward | Company Confidential
Page 30
PARTNERSHIP WITH PRATT & WHITNEY CANADA
SUPPLIER OF EXCELLENCE TO P&WC FACILITIES
OVERHAUL & SPECIALIZED REPAIR OF COMPONENTS
PT6 GAS GENERATOR CASES
PT6 COMPRESSOR STATORS
August 2010 | Moving Our Industry Forward | Company Confidential
Page 31
PT6 GAS GENERATOR CASES
COMPLETE OVERHAUL
August 2010 | Moving Our Industry Forward | Company Confidential
Page 32
DIFFUSER TUBE REPLACEMENT
August 2010 | Moving Our Industry Forward | Company Confidential
Page 33
NO. 2 BEARING HOUSING REPLACEMENT
OIL PRESSURE & SCAVANGE TUBE REPLACEMENT
August 2010 | Moving Our Industry Forward | Company Confidential
Page 34
FRONT & REAR FLANGE REPLACEMENT
OUTER CONE REPLACEMENT
August 2010 | Moving Our Industry Forward | Company Confidential
Page 35
BOV & COMPRESSOR LINER REPLACEMENT
August 2010 | Moving Our Industry Forward | Company Confidential
Page 36
FUEL NOZZLE PAD REPLACEMENT
August 2010 | Moving Our Industry Forward | Company Confidential
Page 37
PT6 COMPRESSOR STATORS
COMPLETE OVERHAUL
August 2010 | Moving Our Industry Forward | Company Confidential
Page 38
VANE REPLACEMENT
100% & PVR
August 2010 | Moving Our Industry Forward | Company Confidential
Page 39
F.O.D. DAMAGE TO VANES
August 2010 | Moving Our Industry Forward | Company Confidential
Page 40
REMOVE VANES
August 2010 | Moving Our Industry Forward | Company Confidential
Page 41
DIAMETER RESTORATION
August 2010 | Moving Our Industry Forward | Company Confidential
Page 42
Content
Chromalloy
Organization Chart
Chromalloy capabilities
PWC Divisional Support
Chromalloy U.K
Chromalloy France
Chromalloy Dallas
OpEx and Turnaround time Focus
August 2010 | Moving Our Industry Forward | Company Confidential
Page 43
Operational Excellence
Lean Manufacturing closed & on-going
PW100 HP Vane Segment
Line organization
Standard Work in place
Tooling
TAT reduction from 35 cal days to 15 cal
days
In process PW100 PT VR 2nd stage
PW100 Turbine Interstage Case
Line organization
Standard Work in place
Tooling
TAT reduction from 30 cal days to 15 cal
days
1st target achieved regularly in Oct 09
New target at 12 cal days
TAT today at 19 cal days
Achievement goal for end Sept 10
PW100 LP VR Solid & Aircooled & PW100 PT VR 1st stage
PW901 / JT15 HT & PT Stators
& PW206 / PT6 PT VR & CT VR
PW100 / PT6 / PW901
& CC Inner Liner & CC Outer Liner
Chromalloy Operational Excellence
August 2010 | Moving Our Industry Forward | Company Confidential
Page 44
Operational Excellence
Chromalloy Operational Excellence
August 2010 | Moving Our Industry Forward | Company Confidential
Page 45
TAT & TTQ
Turn Around Time & Time To Quote
TAT
TTQ
Trans Inc
Exchange
TAT
TTQ
Trans Inc
Exchange
PW100 CCIL
15
6
YES
JT15 SMED
16
6
NO
PW100 CCOL
21
6
YES
PT6 CCIL
19
5
NO
PW100 HP S
9
4
YES
PT6 CCOL
25
5
NO
PW100 HP T
12
4
YES
PT6 COMP STATORS
25
5
YES
PW100 HP T II
15
4
YES
PT6 CT
31
6
YES
PW100 LP PH II
25
5
YES
PT6 GG CASE
20
5
YES
PW100 LP S
20
5
YES
PW206 CT
30
4
NO
PW100 LPTH
20
5
YES
PW206 PT
35
5
NO
PW100 PT1ST
18
5
YES
PW901 CCIL
12
4
YES
PW100 PT2 BLADES
15
5
NO
Regional Logistical Support
PW100 PT2ND
20
5
YES
Strategically based Account Managers - providing "time zoned"
PW100 SMED
15
5
NO
customer / technical support
PW100 TED
25
5
YES
PW100 TIC
19
5
YES
PW100 TSC
25
5
YES
1 to 10 d
1 to 10 d
On site support with 24 hours "worldwide"
AOG / HSI Support thru Component Pool / exchange programs
Chromalloy TAT
August 2010 | Moving Our Industry Forward | Company Confidential
Page 46
Chromalloy Engineering
New Developments program
PW500 Gas Gen Case – CUK
Rear Flange Replacement.
Manual Generic Repairs.
( Pending PWC Approval ).
PW200 TSC Generic repairs – CUK
PW100 HP & LP Shroud Segments – CUK
LPPS application to segment .
( Awaiting data from PWC).
August 2010 | Moving Our Industry Forward | Company Confidential
Page 47
August 2010 | Moving Our Industry Forward | Company Confidential
Page 48