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no. 25 july 2004

news and update by Satair - a leading company within aircraft parts distribution

30 years’ anniversary for Satair and B/E Aerospace

2

Editorial

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Satair exclusive distributor for CWF - Chemie Frankfurt GmbH

6

Farnborough International Satair introduces new website

The UK integration process continues smoothly

Asia Aerospace 2004 in review

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Servicing your beverage requirements New standard in coffee making, the Endura™ beverage maker 30 years’ anniversary for Satair and B/E Aerospace

5

Pall Aerospace Introduces new filter for the Boeing 737 Airbus cargo loading system New corporate customer development function

Satair Hardware ‘In Brief’

7 SHG’s manufacturing capability Claverham Limited

8

Quiz! A brief history of wind tunnels The icing wind tunnel

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editorial no. 25 july 2004

Publisher: Satair A/S, Copenhagen, Denmark E-mail: [email protected] Editor: Camilla Schuricht Design & Layout: Relevans Print: JP Trykservice A·S Circulation: 11,000 Satelite is published twice a year by Satair. All rights reserved. No part of this publication may be reproduced, stored in retrieval system or transmitted, in any form or by any means, without prior written permission by the publisher.

SATAIR A/S Amager Landevej 147A 2770 Kastrup, Denmark Phone: Fax: AOG Service: SITA:

+45 3247 0100 +45 3251 3434 +45 4040 1224 CPHSA7X

SATAIR USA, Inc. 3993 Tradeport Boulevard Atlanta, GA 30354, USA Phone: Fax: AOG Service: SITA:

+1 404 675 6333 +1 404 675 6311 +1 404 310 1966 ATLSA7X

SATAIR ASIA Pte. Ltd. 8 Loyang Link 508897 Singapore Phone: Fax: AOG Service: SITA:

+65 6543 0977 +65 6543 0737 +65 6543 0977 SINSA7X

Charles Darwin famously remarked that it is not necessarily the strongest that survive but the most adaptable. These words, which were originally said about the evolutionary race, in many ways apply to the aviation industry today. The aerospace market is changing, and to survive its players must evolve and adapt. As a leading supplier, Satair is highly dependent upon its ability to adapt to the market’s requirements and adjust its product offerings and business model on an ongoing basis. For almost half a decade, Satair has demonstrated its ability and readiness to adapt to the ever-changing environment and we intend to keep up the pace. In the coming years, Satair will continue to build upon its service concept business models by identifying opportunities in the marketplace and developing its capabilities to capture these. One of Satair’s focus areas will be the development of Service Provider solutions to the Aftermarket, as we see more and more customers requesting or preparing to request such services. IPP® (Integrated Purchasing Program) celebrates its 5th year at the end of 2004. Developed in close cooperation with Airbus Satair IPP is an example of a successful service concept for both suppliers and aftermarket customers. For further information I encourage you to visit our website www.satair.com.

Service provider solutions have for a long time been a fully integrated part of our hardware business. For many years, Satair Hardware Group has offered service provider solutions such as bar-coding, DLF (Direct Line Feed), JIT (Just in Time), lean supply kitting and management of customer own stock. These years of hands-on experience form a perfect platform to develop new solutions targeted at the Aftermarket, and we look forward to seeing what the future will bring. As we continue to work on these new developments, we are proud to be able to keep introducing you to new suppliers and new products from our existing supplier base. In this issue of Satelite you can read more about new products from B/E Aerospace and Pall Aerospace – both suppliers to Satair for many years. Additionally, we can introduce you to products from a manufacturer with whom our business relationship is much younger CWF-Chemie is a company with whom we have established a relationship through the Integrated Purchasing Program, and it has contributed to a strengthening of Satair’s product portfolio. As always I will encourage you to read the section especially dedicated to our hardware business, which can be found on page 6. Welcome to this issue of Satelite.

SATAIR MALAYSIA Foreign Branch 311, Block E, Kelana Parkview No. 1, Jalan SS6/2, Kelana Jaya 47301 Petaling Jaya Selangor Darul Ehsan, Malaysia Phone: Fax: SITA:

+603 704 6657/6670 +603 704 6691 KULSA7X

SATAIR CHINA Representative Office CASC Airbus Tianzhu Airport Industrial Zone Tianwei Erjie Shunyi County, P.O. Box 3412 101312 Beijing People's Republic of China Phone: Fax:

John Stær

+86 10 8048 6340 +86 10 8048 6599

Farnborough International July 19 – 25, 2004 by Camilla Gregor Schuricht, Marketing Coordinator, Satair A/S

www.satair.com

SATAIR HARDWARE UK LTD. Head Office Shoreham Airport Shoreham by Sea West Sussex BN43 5FN, United Kingdom Phone: Fax:

+44 0 1273 464046 +44 0 1273 464577

SATAIR HARDWARE UK LTD. Purdeys Way Purdeys Industrial Estate Rochford Essex SS4 1NE, United Kingdom Phone: Fax:

+44 0 1702 202553 +44 0 1702 206248

SATAIR HARDWARE A/S Amager Landevej 147A 2770 Kastrup, Denmark Phone: Fax:

+45 3247 0100 +45 3247 0192

SATAIR HARDWARE S.A.S. 27 Av. Etienne Audibert BP 30169 60305 Senlis Cedex, France Phone: Fax:

+33 3 4421 6868 +33 3 4453 4999

SATAIR HARDWARE INC. 650 SW 34th Street Suite 304 Ft Lauderdale Florida, FL 33315, USA Phone: Fax:

+1 954 359 1694 +1 954 359 1698

www.satairhg.com

This aerospace exhibition and flying display is held every two years at Farnborough in Hampshire. It is the largest temporary exhibition in the UK, and one of the most internationally attended aerospace events of all the large aerospace exhibitions in the world. It is a perfect venue for the world's civil and military aerospace suppliers and their customers to meet and discuss current and future business opportunities. Satair and Satair Hardware Group are very pleased to once again welcome you to their stand at Farnborough.

You will find us in

HALL 1, STAND C10 You will be able to meet both representatives from the Aftermarket and the OEM divisions. For the first time, since Satair's acquisition of Lentern (Aircraft) Limited - now a part of Satair Hardware Group, you will have the opportunity to meet us face-to-face and hear more about how Satair and Satair Hardware Group are now in an even better position to provide a complete and integrated service to the customers.

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3 Servicing your beverage requirements By Brian Hvid, Lead Buyer/Logistics Manager, Satair USA Two years ago, B/E Aerospace began the difficult process of consolidating business units. As part of this initiative B/E's Delray Beach Florida (Beverage Maker) facility was moved to Lenexa, Kansas, and integrated with the B/E Aerospace Oxygen Systems Products Division. In connection with the consolidation, B/E evaluated its aftermarket support arrangement and decided to strengthen this area by appointing Satair distributor of B/E Aerospace Beverage Maker Products. In this role, Satair provides service to all Repair Stations, MRO’s, FBO’s, General Aviation and Corporate Aircraft operators worldwide

Satair's sales teams have contacted customers to inform them of this exciting news and to discuss how we can best serve our customers in regard to B/E Aerospace Beverage Products spares requirements. We understand the emphasis each airline places upon the desire to provide the flying public with the utmost comfortable and satisfying flying experience. Clearly, beverage service and quality play a significant role in passenger satisfaction. Satair aims to ensure that the airlines are well equipped by servicing their beverage product needs in a timely manner. B/E Aerospace and Satair are excited about expanding this service, support and supply of spare parts manufactured by B/E Aerospace Beverage Maker Products.

Today, we are proud to announce that B/E has extended its agreement by appointing Satair distributor for designated airlines worldwide. On February 3, 2004 the agreement was signed into effect by Mr. Rao Tella, Vice President, B/E Aerospace and Mr. Steen Karsbo, Product Marketing Manager, Satair A/S and the extended aftermarket agreement was implemented on May 17, 2004. B/E and Satair formed a relationship to support Airlines worldwide over 30 years ago. This alliance has been a very positive one for both parties, but more importantly has provided a higher degree of support to the Airlines who rely on us for support and service.

Mr. Kevin Welch, Program/Contracts Administrator, B/E Aerospace introduces the Endura - the newly developed, innovative beverage maker. This picture was taken during a training session in Copenhagen on April 5, 2004.

30 years’ anniversary for Satair and B/E Aerospace

Now serving a larger customer community Satair has significantly increased the inventory holdings of B/E Aerospace Beverage Marker Products around the world. Until recently all inventory was carried in our Atlanta, USA facility, however, now both our Copenhagen and Singapore facilities carry inventory to service our customers' needs from regionally based stock locations.

By Karina Bergstøm Larsen, Product Manager, Satair A/S The total oxygen solution, ATA 35 In 1967 during the Paris Air show, Satair’s founder Mr. Knud Sørensen, had the first meeting with founder and President of Zep Aero, Mr. Wilbert J. Zepp. The meeting was to introduce the two companies to each other. Satair had the aim to become the distributor of oxygen products in Scandinavia. In 1974, the first official distribution contract was signed and ever since the relationship has grown.

A new standard in coffee making, the Endura™ By Tina Tang-Jensen, Product Marketing Coordinator, Satair A/S beverage maker Satair is proud to offer you the Endura™ Beverage Baker manufactured by B/E Aerospace. The Endura™ is set to become the new standard of quality, reliability and value for airline beverage makers. Superior product performance, innovative, breakthrough technology are just a few words describing the new Endura™ Beverage Maker. Designed in cooperation with the airlines and for the airlines, the Endura™ beverage maker from B/E Aerospace fulfils all the requirements for an airline Beverage Maker. The Endura™ is the solution to your need for a cost efficient beverage maker. It simplifies maintenance with 30% fewer parts and the easy-access design results in less downtime and lower maintenance costs. On top, the Endura™ Beverage Maker offers a mean time between failure of 4,000 hours. Key reasons for converting your present beverage maker to the Endura™

■ designed for a mean time between failure of 4,000 hours. ■ offers low cost of ownership. ■ designed to work seamlessly with existing galleys and servers. ■ incorporates advanced technological features that improve the quality of the coffee brew. ■ optimised for ease of maintenance to facilitate quick, simple component service or replacement. ■ employs several ergonomic features to make the unit comfortable and easy to use. ■ designed with a non-contact liquid level sensor ensuring a reliable and accurate volume of beverage dispensed into the server. ■ utilizes multiple redundancies throughout the design to further enhance reliability. ■ winner of the prestigious ‘RED DOT’ industrial design award in March 2004. To obtain further information on the Endura™ beverage maker, please contact your local Satair representative by telephone: Satair A/S at +45 3247 0100, Satair USA Inc. at +1 404 675 6333 or Satair Asia Pte. at +65 6543 0977.

Later Zep Aero became Puritan Bennett, which today is known as B/E Aerospace and the oxygen products are manufactured by B/E Aerospace, Lenexa in Kansas, USA. In 1999 the relationship between Satair and B/E Aerospace grew even further, and Satair became the exclusive global distributor of oxygen. Today, Satair services both airline, special military and OEM projects with the concept “The total oxygen solution”, which reaches from pilot and passenger masks to support to passengers, who may require therapeutic oxygen during their flight. Recently, Satair has extended its business to also include supply of beverage maker spares from the B/E Aerospace Lenexa facility to the airline market and MROs. For further information regarding this agreement please see the article “Servicing Your Beverage Requirements” on this page. In short, Satair is happy to celebrate the 30 years of experience with oxygen and the experience gathered during these past many years and Satair appreciates that we can supply the customer base with experience, latest products and on time deliveries.

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4 Satair exclusive distributor for CWF - Chemie Frankfurt GmbH by Anette Juel Sørensen, IPP Vendor Liaison Coordinator, Satair A/S We are pleased to inform you, that CWF has appointed Satair as exclusive worldwide distributor and AOG Center in accordance with the CWF-Chemie Frankfurt aftermarket support strategy. The distribution agreement is effective immediately and involves product marketing and aftermarket sales support for CWF-Chemie Frankfurt’s portfolio of soap dispenser systems as well as the associated spare parts and soaps for these dispenser systems. The new distributorship is managed by Satair’s Integrated Purchasing Program (IPP®), which is an integrated purchasing concept developed in cooperation with Airbus and a part of the Airbus Spares Clustered Shopping concept. CWF-Chemie Frankfurt GmbH, cage/FSCM 120C2, is a German manufacturer of liquid soap dispensers for the aerospace market. The company was founded in 1972 and represents more than 30 years of experience with manufacturing of liquid soap dispenser systems for use onboard aircraft (lavatories and galleys). To service its customers, Satair will stock a variety of soap dispenser systems series B82X and D99X applicable for Airbus A300, A310, A320 family, A330 and A340 aircraft along with the liquid soap and spare parts needed for these systems. As of March 2004, the lockable dispenser system (i.e. the K-version) has been replaced by a non-lockable version. As a consequence, turning the cover counterclockwise now easily opens all dispensers. These changes are included in the revised ACMM No. 25-40-01 dated March 10, 2004.

Asia Aerospace 2004 in review by Jenny Li, Senior Area Sales Manager, Satair Asia Singapore – the rainy season of 2004 stopped right before end February. After few months of rain-washing, the clear blue sky of this tropical country was just ready for the opening of Asian Aerospace 2004. More than 750 exhibitors in international aviation community gathered in Singapore from February 24 to 28 to celebrate the biggest industrial event in Asia Pacific. Although the tragedy of September 11 and the drama of SARS remain fresh, the show still sets a new record of trade visitor turnout with over USD3.2billions worth of deals announced. While the last airshow focused very much on air safety and in-flight anti-terrorism measurements, this airshow sets a great platform for new technologies, new ideas and new adventures. The USD1billion fighter replacement program for (Singapore Air Force) RSAF’s was probably the most expected deal in the airshow. It certainly generated much public interest and put the latest military program under the spot light. An exciting battle was sparked among Boeing’s F-15, Dassult’s Rafle and Eurofighter’s Typhoon. The flight demo preludes the show time. When those iron birds roared under the sun of Singapore in front of thousands of spectators, their great flexibility was demonstrated to full details by making the most difficult and delicate movements within a split second. One has to bow to the progress of aerodynamics, which only started by a man-powered flying machine a mere hundred years ago. The power overwhelmed the audience, making it a privilege to watch the demo flights. It doesn’t take any great effort for everybody under that hot sun to be proud of this flying era. We, the human beings, have indeed made a huge difference in conquering the sky.

Another eye-attracting spot in the airshow was the China ARJ program. With extensive cooperation of major leading system providers in aviation, China has brought its solid intention of regional passenger aircraft, ARJ, all the way to the airshow. The ARJ was launched in Shanghai last December. A nicely built cabin prototype was displayed at the show, attracting many of the visitors. The 70 to 90-seat regional jet is scheduled to be certified by FAA in year 2007 and enters into the global aviation market with full swing. With the most promising economy in 21st century, China will not only dominate the growth in new aircraft purchasing and passenger growth, but also fight for a fair share of modern aircraft technology. The airshow has always been a meeting point for airlines. Being the new kids on the block, the Asian low cost carriers (LCC) have triggered many discussions and speculations over the airshow. The Singapore sky is already packed with at least three LCCs in end February, namely Air Asia, ValueAir and TigerAir. All of them with tender age in operation but great ambition. Right before this article was written, another LCC JetStar Asia was also set to fly. All of them will be focused on routes with 5-hours’ distance from Singapore, a highly competitive market segment in Southeast Asia. Suddenly, the national carriers in Asia will no longer be in a position to dominate the busy Asian Sky. Can the LCC model work in Asia? It will be a million-dollar question posted to the management of these airlines…. and the vast amount of travelers in Asia. The airshow folds with great deal of memories, ambitions and thoughts. We all hope the new ventures will continue after the show, heading towards the recovery and prosperity of aviation.

Please contact Satair for your next requirements of soap and soap dispenser systems manufactured by CWF-Chemie Frankfurt GmbH. For further information on Satair’s portfolio of products from CWF-Chemie Frankfurt, please contact the Satair IPP department at [email protected] or at +45 3247 0100.

Satair introduces new website including an E-news sign up feature By Tina Tang-Jensen, Product Marketing Coordinator, Satair A/S Satair is pleased to introduce its new website incorporating a redefined structure for easy navigation as well as new and additional features for all visitors. One of the new features is the opportunity for you to subscribe to Satair’s E-news service. All you need to do is enter the website on www.satair.com and click on the E-news link located at the top of the right hand side of the screen. Fill in the information as required and you are ready to receive an email alerting you of all news releases within the chosen news categories. Satair welcomes you to its new website and encourage you to sign up for the E-news service.

If you require further information on Satair or any of the products and services offered, please contact your local Satair office :

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Satair Satair Satair Satair

A/S at +45 3247 0100, Asia Pte. at +65 6543 0977 Inc. at +1 404 675 6333 or China at +86 10 8048 6340.

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Side 5

5

Regulator Orifice

Pall Aerospace introduces new filter for the Boeing 737 By Brian Webster, Manager Commercial Sales, Pall Aerospace Pall Aeropower Corporation (PAC) has recently finalized development and testing of a new filter assembly which will significantly improved the reliability of the engine mounted bleed air valves and components on the Boeing 737300/400/500 series aircraft that are equipped with the CFM56-3 engine. After an extensive development program, PAC was awarded an FAA Supplemental Type Certificate (STC), which will allow airlines to install the new Soot Filter Kit (part number CD010861K1T) on these aircraft. Development of this product began in 1995 after United Airlines noted a higher than desired removal rate for the bleed air components on their Boeing 737 fleet. Analysis of the removed components indicated that a sticky, carbonbased compound, which clogged orifices and caused internal valve spools to stick rendered the component inoperable, caused more than 50 per cent of the removals. Further investigations revealed that the common source of this contamination was the "muscle" air that is taken from the 5th compressor stage bleed air duct and is used to regulate and operate these components. Following these investigations, PAC in cooperation with United Airlines, CFMI and Boeing developed a new filter assembly that is installed in the muscle air line between the 5th stage bleed duct and the affected components. Developed of high strength metals, this filter is designed to withstand the rigors induced by 500 0F bleed air and the high vibration environment created by being mounted directly to the engine. Pall Corporation has patented the unique media used in the filter element of this design.

Y-guide open

After developing a suitable configuration, PAC installed the new soot filter on an engine at United's SFO facility and conducted a vibration survey as the engine was run in the test cell. The results of this survey were reviewed and approved by CFMI. Tom Hansen After completing the design and development phase, United Airlines installed the soot filter on two aircraft for a full C-Check interval flight evaluation. On these aircraft, previously fitted with freshly overhauled bleed air components, a soot filter was installed on the number two engine while the number one engine was left unprotected in order to provide a side-by-side comparison of the condition of the associated components at the end of the flight evaluation. In March 2004, following approximately 3500 flight hours of use, United Airlines tore down the flight evaluation components and their internal condition examined. It was clearly evident that the components protected by the soot filter contained significantly less contamination than the unprotected units as exhibited in Photo 1. By incorporating the Soot Filter on its Boeing 737 fleet United is expecting to decrease the number of unscheduled component removals by at least 50 per cent. The final phase of this program, currently underway, is to obtain a Service Bulletin or Service Letter from Boeing introducing the Soot Filter as an approved installation for the Boeing 737 aircraft. Satair personnel will be provided a complete launch package for this product in July 2004.

Y-guide closed

New corporate customer development function Satair is launching a new sales function, which will focus on addressing new markets and new customers for Satair’s range of products and services. Tom Hansen, a long time and experienced Satair employee, heads this function. Tom has worked as Sales Manager in various sales departments of Satair towards a wide range of different customer segments, and the last six years he has worked on developing the sales to Defence customers in Europe. Start of the activities in this new function will be as of July 1, 2004 and the main objectives will relate to exploring new customer potentials, establish new accounts and interact with Satair’s suppliers to ensure complete market coverage for the benefit of the complete supply chain.

Cargo deck

Y-Guide, the Airbus cargo loading system By Cameron Share, Product Manager, Honeywell Sensing and Control

For many years Satair has distributed Honeywell Sensing and Control products throughout the world. Building on this very successful relationship, Honeywell is delighted to appoint Satair to support aftermarket activities on its Airbus Cargo Loading System products. Satair will now stock replacement systems and spare parts for supply to the airline community.

The Cargo Loading System is used on the cargo deck of various Airbus commercial aircraft to control the movement of baggage containers. The main part of the System is called the "Y Guide", and can best be described as a large hinge. When lying horizontal to the cargo deck, it allows free passage of containers, but when operated, integral motors move the hinge to a vertical position, preventing movement of the containers.

sensor products, has a strong business infrastructure and full aerospace approvals including AS9100, JAR21 and JAR145 for maintenance and repair.

The System is used across a number of Airbus aircraft including A300, A310, A310F, A330 and A340. Manufacture of the System takes place at Honeywell’s factory at Newhouse in Scotland. This award winning facility, which already designs and manufactures switch and

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Side 6

6 Goodrich and SHG teams at contract signing

The UK integration process continues smoothly “On time, on budget and to the required standard”: this was the message given to the teams at Shoreham and Southend at the start of the process which will see the transformation of Satair Hardware Limited and Lentern (Aircraft) Limited into Satair Hardware UK Limited.

Nigel Thomas

The end goal is simple: to amalgamate two separate and successful companies into one entity that will hold an unrivalled position as the UK’s and Europe’s largest, strongest and most credible hardware distribution business. But how to do this “on time, on budget and to the required standard” is more complex. To successfully implement such a move has demanded a thorough understanding of each area of the business, detailed planning, widespread consultation and a comprehensive project management methodology. Integration Director Nigel Thomas has been brought in to oversee the process and to manage the smooth amalgamation of the companies. “Integration is one thing; complete integration while maintaining service levels and customer confidence, is another“, confirms SHG’s CEO Rod Scott. “Happily the process has gone relatively smoothly so far, and we’re already seeing the benefits that drove the acquisition in the first place.

“Thanks must go not only to the dedicated team involved, but also to all those members of staff who have worked tirelessly to make the integration a success.” The planned 12- to 18-month integration period began with Nigel’s appointment on 5 January this year. Now, several months later, the project is still fulfilling the three essential requirements, but this has not been achieved without a well-planned strategy and the co-operation and hard work of the merging workforces. The complex process takes in three areas: the first two are the re-organisation of the commercial and warehousing functions so that most of the buying, selling and customer support will be based at Shoreham, and warehousing at the Purdeys Way facility in Southend. The third aspect is manufacturing. Currently this is based at Southend Airport, but it is planned to also move this operation to Purdeys Way.

So how is all this being achieved? One of the first moves was to introduce PRINCE 2 (Projects in Controlled Environments) – a project management methodology which can be described as a structure or a set of rules on communication, management of tasks and planning. In simple terms, it is a structured way to approach projects and is an essential piece of the armoury that will achieve the end goal. Next the integration process was split into seven different areas: IT; Warehouse; Commercial; Human Resources; Buildings; Finance and Quality. An in-depth analysis of each area had to be carried out to gain a full understanding of the current situation in each area of the business. Within each of these categories, project groups have been set up, and throughout the working week Nigel spends time in each department and meets with individual groups, helping to progress the tasks associated with each project group. An integration team consisting of all the directors has also been set up, and it meets every week to report on progress.

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“It is important that the views of all the parties involved are represented,” says Nigel. “We want to make sure that we do not miss anything of value in merging the two businesses together. I really want to build upon a people-centred culture ensuring that it is task-focused and goal-orientated.” While the physical changes to the buildings will take time, the plans are already in hand. The technical issues involved in the move to introduce SHG’s IT system across the board make it a more complex process, but a strategy is in place and a solution has been found. The staff are a key consideration in the integration process, and it is the emotive issue of reducing staff numbers that has demanded the most care and attention. There has never been any denying that such major changes in two companies will inflict pressures and strain on employees. Whilst a reduction in headcount is essential to ensure the new company continues to work in an efficient, effective and profitable manner, it has been made clear from the outset that compulsory redundancies will be kept to a minimum. However, more than 100 jobs will be lost as part of the phased redundancy programme, with the final phase commencing in July. Consultation and communication at every level and every stage helps to prevent low morale and poor service; and, according to customers, the high level of service synonymous with both companies has not been affected. “One of our major customers has said that they were surprised by the excellent level of service they were receiving given the uncertainty over the loss of jobs,” says Nigel. “This is down to the dedication of many of the long-serving and loyal people within the business. Even in times of dramatic change they are still doing an excellent job.” The involvement of all parties involved has been, and is, a vital part of the integration strategy; briefing customers and introducing them to the new company is essential to maintain the good quality relationships previously enjoyed by both companies. “We have worked closely with several of our major customers to understand what the major issues are for them in our business relationship,” says Nigel. There is no doubt that during the next 12 months more hurdles will have to be cleared in a bid to reach the “on time, on budget and to the required standard” goal. But with such a detailed strategy in place, it is clear that confidence is high all round and that the full integration will be achieved to the company’s high standards, enabling Satair Hardware UK to reach new heights within the aerospace industry.

‘In Brief’

■ Three-year extension to Goodrich contract We have successfully negotiated a three-year extension to our existing contract for the supply of fasteners and associated products to Goodrich Control Systems Ltd at Shaftmoor Lane, Birmingham. ■ New DLF contract with Westland Transmissions We have just signed a three-year direct line feed (DLF) contract with the Westland Transmissions Limited (WTL) manufacturing facility at Yeovil in Somerset. Implementation begins immediately, and the value of the contract is estimated at around USD2million per annum once the contract has matured. WTL is a major sub-contractor to Westland Helicopters and manufactures the main rotor-head gearboxes that are used on the EH101 and Lynx helicopters. WTL decided that a DLF system could offer it significant benefits and savings, having studied the Satair Hardware system that has been successfully operating at Westland Helicopters.

■ Monogram Aircraft Fasteners SHG has been working with MAF for three years, and the distributorship agreement has now been extended to a worldwide one. The extended territory offers many more sales opportunities, and we can now work on a global scale as far as procurement and prices are concerned. MAF produces a wide range of highly engineered fasteners and is a key player in this aerospace sector. Strengths include the supply of blind fasteners, particularly fasteners for composites. This is important for SHG as composites are used intensively amongst our customers. ■ DLF with Mazères-Aviation We are pleased to announce a new DLF programme with Mazères-Aviation in France. Today, this is worth about USD250,000 annually, but at the moment only includes the Airbus A320. We expect to extend it to other sub-contact work Mazères undertakes for customers such as Embraer, Dassault and ATR, so the potential is far higher.

■ Click Bond distributorship extended SHG is pleased to announce the extension of its distributorship with Click Bond to include the territory of Malaysia. The extension became effective in February 2004 and covers all products, technical support and sales support. Click Bond manufactures fasteners specifically designed for adhesive bonding to structures that SHG uses to support a wide variety of customers. For the future, SHG expects that sales of Click Bond products and the distributorship will continue to strengthen as composite material uses are extended. ■ New sales positions Daniel Poiret, VP of SHG Sales, is pleased to welcome some new members into the sales team. Phil Hawes is joining the UK sales team as Product Sales Manager. Dick Edwards, as OEM Sales Director, will be responsible for North America, replacing Bill Walker. Our thanks go to Bill for all the good work he has done for SHG over the past two years, and we wish him a happy retirement. Also reporting directly to Daniel will be John Williams, Group Manager for DLF Sales.

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7 Fixed Head CNC lathe with live tooling

A selection of SHG’s manufactured parts

SHG’s manufacturing capability One of the assets resulting from the acquisition of Lentern (Aircraft) Limited is a 1,000 square metre manufacturing operation situated at Southend airport in Essex. This will shortly double in area when it moves to the Satair Hardware UK Limited’s (SH UK) building at Purdeys Way, Southend which is being refurbished to accommodate the logistical and manufacturing capabilities plus some of the business functions.

manufacturing output consisted of standard-specification nuts, bolts and similar items,” explains SH UK’s works manager Colin Wellham. “When aircraft designers moved to specifying mainly US-standard parts, we quickly realised that we could no longer compete with the large US-based suppliers. We had to develop more specialist skills and concentrate on producing some of the more niche and exotic parts required on today’s aircraft assembly lines.

To assist its customers to make use of best practice, as well as passing on over 60 years of acquired manufacturing expertise, the Southend manufacturing facility offers a complete engineering research, design and development capability, which is proving a particular success with key customers.

“Now we’ve built up a deserved reputation for an ability to work with our customers, brainstorm new solutions, build prototypes and supply high-quality specialist parts to a tight schedule and cost.”

It might seem incongruous that such a relatively small manufacturing operation is still viable in this age of mergers and mass production, but the ability to make intricate parts to an OEM’s exact specification still represents a significant competitive advantage. The main customer benefits are quality, traceability, serviceability, quick response and fast turn-round, taking the cost out of parts by better design and machining, the ability to produce low-volume niche products at competitive rates; and the design and manufacturing know-how of a team skilled in the art of precision engineering. Over the past 20 years, the hardware market has changed considerably. “In the mid-80s almost our entire

Claverham Limited Claverham Limited is one of the ‘new’ customers recently acquired by the Satair Hardware Group, and is an established world leader in actuation technology. After the management bought Fairey Hydraulics from the Fairey Group in 1998, it decided to change the name to that of the Somerset village near Bristol where Fairey Hydraulics had been based since 1982. Claverham Limited is now owned by Hamilton Sundstrand, one of the divisions of the United Technologies group of companies. Before joining the Satair fold, Claverham had been a customer of Lentern (Aircraft) Limited since 1994, when it started supplying kits of parts (mainly seals) for the Tornado. Then, five years ago, the involvement grew with the implementation of a new direct-line feed (DLF) system, won by Lentern in a bid process against stiff competition. This system manages the supply of fasteners, seals and small electrical items. It has improved the availability and the kitting of these parts, and greatly reduced the workload at the Claverham stores. Jo Edwards, head of operations at Claverham’s customer service team anticipates a continuing close relationship with Satair Hardware UK: “Although any acquisition announcement causes some concerns at first, we are sure that there will be benefits with Lentern now being part of a larger organisation. We will look forward to developing our DLF partnership still further, but for us the real proof will be an even slicker service and evermore competitive prices. The issues driving the whole aerospace industry are shorter lead

Colin and his team of 36 now manufacture over 6,000 specialist product lines for customers such as Agusta Westland; Airbus; BAe Systems; Claverham; Goodrich; Raytheon and Rolls-Royce. All manufacture is from ’bar and billet’, using state-of-theart multi-axis computer numerical control (CNC) sliding- and fixed-head lathes, which can turn bars from 1mm to 32mm in diameter and up to 300mm in length, with a typical tolerance of 0.01mm. The fixed-head CNC lathes have a chucking capacity up to 250mm in diameter, and complementing this CNC machinery is the latest CAD/CAM technology.

rolling up to 20mm; programmable CNC part marking machines, profilating machines, power presses up to a 20ton capacity, rotary transfer machines, and automatic wirelock drills. There is also a fully-equipped in-house inspection department. The facility holds approvals to AS/EN9100 , as well as many OEM prime approvals including Airbus UK parts 1 and 3, Rolls-Royce and Agusta Westland. In fact Agusta Westland has recognised the Southend team’s expertise in self-locking nut technology by approving it to manufacture the special double-lock nuts specified by the helicopter manufacturer. These are widely used on both the EH101 and Lynx airframes, including the rotor-heads. “The Satair acquisition has certainly changed things in a very positive way,” concludes SH UK operations director Kevin Chandler. “The manufacturing facility has taken on a new lease of life after inheriting six or seven new group customers, and we’ve identified several new opportunities. “It’s perfectly possible to increase capacity if we have to because we’re only running one shift at the moment, and the move to Purdeys Way will give us even more space for additional equipment should we require it. The way the industry is developing, OEMs are bound to need more specialist products and technical expertise in the future, so we will be in the perfect position to take advantage and deliver whatever is required.”

Other specialised equipment includes a Bridgeport machining centre with 16 station auto tool changer thread

Claverham advanced development actuator

times, better quality, faster service, and lower prices. If Satair can deliver these, we will be well satisfied. “We are pleased to report that we haven’t experienced any disruption during the integration process, so all credit to the team at the other end of the telephone. We’re still dealing with the same people – which is important as they fully understand the product range and our requirements.” Claverham has over 40 years experience in the analysis, design, development, qualification and manufacture of equipment, using electro-hydraulic, electro-mechanical, electro-pneumatic and other hybrid technologies. It occupies 92,000 square feet of assembly and office space, and splits its assembly and test facilities into electro-mechanical and hydraulic. Revenue in 2003 was USD79million. Today’s technology means that electro-mechanical actuation is rapidly replacing hydraulic systems – the reason brought home dramatically when comparing the modern intricate and compact electro-mechanical units with their considerably larger and heavier hydraulic counterparts. Customer products include aircraft canopy locks, landing gear, actuators and system designs; helicopter decklocks and rotor actuators, guided weapon and UAV actuation systems, decklocks and landing gear, tank autoloaders, and marine stabiliser and rudder systems, as well as product design and development, full customer support and service programmes, asset management, spares supply, and repairs and overhauls.

The Satair DLF is unusual in that it has to feed Claverham’s new-build, repair and overhaul, and spares requirements. The new-build programme is fairly straightforward because usage is reasonably consistent, but the repairs and overhaul feed can only be calculated on historic usage as different parts are required for whatever units are in for repair. Spares are also subject to ad-hoc customer requirements; historic usage is some guide, but the chief need is for extremely quick reaction times from the supplier. Currently this particular DLF system covers a portfolio of about 700 different parts, but it is likely that this will be increased further as the system works so well. “Claverham is committed to continuous improvement,” adds Jo Edwards, “and part of this involves working with partners to improve our supply chain. We’re a forward-looking company and always identifying ways to improve our competitive edge in the market. “Satair’s experience and willingness to find new solutions helps us immensely in this respect.” More about Claverham and its products can be found at www.claverham.co.uk.

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5250 Satelite no.25

02/07/04

12:42

Side 8

Participate!

A brief history of wind tunnels

1 prize

By Flemming Stelling Ludvigsen, Product Manager, Satair A/S

a Jacob Jensen wall clock

2-10 prize a Leatherman tool

Congratulations to the winners: 1. Wanghijie, Catic Supply 2. Paul Lee-Horn, Sunstate Airlines 3. Steve Bisheden, Britannia Airways 4. Margarita Salvá, LTE Int. Airways 5. Petr Voldau, CSA Czech Airlines 6. Jarno Tuomonen, Finnish Air Force 7. Qing Ping, China Southern Airlines 8. J. von Wilker, TFS Aerospace 9. Joyce Chan, Russell Assciates Inc. 10. Ronald Thielemann, Alcoa Fastening System

Q U I Z N O : 2 5 : J U LY: 0 4 1. How many years have Satair and B/E Aerospace worked together?

2. Which German company has Satair signed an exclusive distribution agreement with?

The First Wind Tunnels In the beginning of the mid-1700s, hopeful airplane designers realized that, if they were to build aircraft that would fly, they had to understand how air moved over aircraft surfaces. Although they observed birds and tried to pattern their aircraft after bird flight, these aircraft uniformly failed. Bird flight did not provide the data they needed. They recognized that to get the necessary data, they had two choices: 1) they could move their test aircraft through the air at the required velocity or 2) they could blow air past a stationary model. The whirling arm was early researchers' attempt at the first method. Several names stand out, Sir George Cayley, Otto Lilienthal's & Samuel Langley, the mathematician, astronomer, and secretary of the Smithsonian Institution, just to name a few, even the Frenchman Gustave Eiffel conducted experiments using a wind tunnel. In the United States, the Wright brothers designed and used a wind tunnel that proved instrumental in the success of the first flying machine. The Wright brothers, working with Octave Chanute, invented and built a simple wind tunnel in 1901 to study the effects of airflow over various shapes while developing their revolutionary Wright Flyer. The Wright wind tunnel was used more recently to test modern low-speed fliers, such as the human-powered "Albatross". It is estimated that it took the Wright Brothers less than 20 hours of wind tunnel testing to produce their successful Flyer (although their empirical research was a life time achievement). The Douglas DC-3, perhaps the most successful commercial aircraft ever built, required about 100 hours of wind tunnel testing. Wind tunnel time has been steadily increasing (and so have the costs) since the Boeing 747 required over 1000 tunnel hours, and the Space Shuttle nearly 10 years of time.

Basic principle drawing: 3. What is the Airbus loading system called?

Facts, data & operational scopes The Reynolds number is the most important dimensionless number in fluid dynamics providing a criterion for dynamic similarity. It is named after Osbourne Reynolds (1842-1912). The Reynolds number is used for determing whether a flow is laminar or turbulent. Some operations ordinarily performed in the wind tunnel are: ■ Drag/lift measurements on aircraft, helicopters, missiles, racing cars. ■

Drag/lift/moment characteristics of airfoils and wings.

■

Static stability of aircraft and missiles.

■

Dynamic stability derivatives of aircraft

■

Surface pressure distributions on nearly all systems.

■

Flow visualizations (with smoke, oil, talcum).

■

Propeller performances (torque, thrust, power, efficiency, etc.).

■

Performances of air-breathing engines.

■

Wind effects on buildings, towers, bridges, automobiles.

■

Heat transfer properties of engines and aircraft.

■

Some of the operations listed above can be performed in a water tunnel.

Conclusion With the invention of wind tunnels, the aeronautical world has greatly improved and expanded. Whirling arms, the precursor to wind tunnels, were an introduction to a whole new world of information. It was only 100 years ago when the Wright brothers became the first in flight, mostly due to flight testing in a wind tunnel. Without wind tunnels, vital information in these fields would leave scientists without explanations to many aeronautical questions. Wind tunnels serve a very important purpose in helping scientists to better understand the concepts of aerodynamics today. (source: Wind Tunnels by Ali Rotondo and Amanda Sayed)

Satair & Satair Hardware employees and their relatives cannot enter the competition.

Company: Name: Title: Address: Postal code/City:

The icing wind tunnel

Country: By Flemming Stelling Ludvigsen, Product Manager, Satair A/S Send, fax or e-mail your answers to Satair before November 1, 2004 Satair A/S Amager Landevej 147A DK-2770 Kastrup Denmark Telefax: (45) 3251 3434 Email: [email protected] Attn.: Camilla Schuricht

N O : 2 5 : J U LY: 0 4

The icing wind tunnel used at Aerazur, a global leader in pneumatic de-ice boot and fuel cell development is designed in-house to support Aerazur’s research and development efforts. It operates to support and innovate Aerazurs design within mainly pneumatic de-ice boots areas, as well as customer programs and academic studies. Varied operational modes and complex instrumentation make the wind tunnel capable of ice properties analysis, ice shape casting and drag analysis, in addition to routine ice shed testing on vaired airfoils and structures. Computers can then record a variety of data, including high speed and remote control video footage on CD or tape media. Should you have a specific project and need to use a wind tunnel, expert technicians and engineers at Aerazur can help you design a test plan and data program. The test centre is located one hour west of Paris, France. For further information and availability, please contact Product Manager Flemming S. Ludvigsen – email: [email protected].