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Intersecting the Future in
Aerospace Composites Manufacturing
Presented by:
Paul Marks
CEO, Argosy International
Overview
About Argosy
Composites Industry & Aerospace Market
Trends
Asian Market Trends
Intersecting the Future: Strategy
Intersecting the Future: Supply Chain
Conclusions / Questions
Acknowledgements
Argosy Confidential & Proprietary2
About Argosy
Argosy Confidential & Proprietary3
Founded in 1988
The leading supplier of advanced composites and supplies to the
aerospace and composites industries throughout Asia
Manufactures aluminum honeycomb in China for export to global
markets in a joint venture with Xian Aircraft
Provides comprehensive logistics services world wide
Argosy’s Business
Argosy Confidential & Proprietary4
Manufacturing DistributionValue Added
Distribution
Services
Honeycombs
Prepregs
Toll manufacturing
Non-wovens
Kitting / cutting
Aerospace coatings, blending / packing
MRO composite material supplies
Core machining
Composites / coating / cores
Warehousing
Haz mat / DG
Cold / frozen
Composite raw materials
Logistics
Global Coverage
Argosy Confidential & Proprietary5
Argosy is positioned in growing / difficult to serve
markets with manufacturing and sales services to
interface with suppliers and global customers
USA
FranceChina
India
S. Korea
Japan
Taiwan
Hong Kong
Malaysia
Australia
Argosy Confidential & Proprietary6
Composites Industry &
Aerospace Market Trends
Y2014 to Y2030 need 30,000 100+ seat aircraft (US$4.1 trillion)
World air traffic – growing 5% per year
˗ Y2014 5.9 trillion passenger KM
˗ Y2030 12.6 trillion passenger KM
Explosive sales – “The biggest aircraft contract in history…” Emirates
space150 Boeing 777x, 50 Airbus 380s, US$100 billion
New aircraft models – 777x, 737 MAX, A350 XWB, A320 Neo, C Series, MS
21, C919, MRJ, ARJ21
Cost-efficient aircraft, e.g., replacing A340 fleet reduced Emirate’s fuel costs
by 25%
Continued high growth over the long term (20 years)
Argosy Confidential & Proprietary7
Industry / Aerospace Market Overview
Delivery build-rate issues (short fall)
˗ Orders increased 6.5% past ten years
˗ Deliveries increased 4.7% past ten years
˗ Backlogs have been consistently increasing
Future – greater consolidation
˗ Risk sharing becomes more global
˗ Primes - systems architects and integrators
˗ Tier manufactures, esp. T1, provide higher integrated systems / “Work”
continues to be pushed down
Industry / Aerospace Market Overview
Argosy Confidential & Proprietary8
Argosy Confidential & Proprietary9
Industry / Aerospace Market Overview
Areas of Focus for Aviation Industry
Performance
Profitability
Optimizing production processes and value
chains
Communication – IT / Cloud interface
World fleet to double in size over the next 20 years
- 38,050 new airplanes
- $5.6 trillion
Emerging markets to lead growth next 20 years˗ 244% increase in plane deliveries to Asia-Pacific
˗ 246% increase to Latin America
˗ 276% increase to Middle East
Strong sales in developed markets– $2 trillion to Europe and NA alone
Argosy Confidential & Proprietary10
Commercial Aircraft Market Forecast
2014 2034
Composites in Aerospace
Argosy Confidential & Proprietary11
Weight savings, high corrosion resistance, long life
span and design flexibility recognized as key
enablers for next generation aircraft
Aerospace Composites Sales
2016: $11.12 billion
2024: $15.40 billion
CAGR: 4.1%
70 milLbs.
Past 50 years 70 million lbs
Next 5 years 70 million lbs
Argosy Confidential & Proprietary12
Asian Market Trends
China
China’s indigenous commercial aircraft OEM effort
- Multi – decade effort
- Wide body and engines
- Improved supply chain capabilities
- Internal market
Subcontract work for Western OEMs
Subcontract / supply for Chinese OEMs
Next 20 years- China will purchase >5000 large commercial
aircraft
- Y2023 exceed 1 billion traveler market
Strong long term growth in private aviation- 10 years will see western style open skies
Argosy Confidential & Proprietary13
Select Platforms
ARJ21
C919
C929
MA700
South Korea
Indigenous aerospace
work is military centric
Multiple new programs:
- Drones
- Helicopters
- Fighters
- Missiles
- Rockets
Large subcontracting
work for Boeing
Argosy Confidential & Proprietary
Select Platforms
KFX
B737 MAX
14
Intersecting the Future:
Strategy
Argosy Confidential & Proprietary15
Industrialization of composites Automation
- Design and simulation
- Manufacturing
- Testing and certification
- Repair
Process controls
Real time tracking
- Visibility into production floor
Digital information
- Green, paperless reporting
Smart components
Argosy Confidential & Proprietary16
Argosy leverages digital
technology for increased
automation in support of
our customers
Intersecting the Future: Strategy
Intersecting the Future: Strategy
Argosy Confidential & Proprietary17
Argosy supports lean manufacturing
Industrialization of composites (cont’d)
Traceability from raw material to finished goods (extending back on
the digital thread)
Production and inventory planning improvement by process
automation
Serving audit and quality requirements
Reducing waste
Eliminating errors
Dashboard and reports
Intersecting the Future: Strategy
Argosy Confidential & Proprietary18
Problem: Loss of control with increasing volume eliminates
economies of scale and results in excessive waste
No contractor in the aerostructures industrial base will be
untouched by the need for this competency
Real-time visibility of production assets is fundamental
to sustainable cost reductions and quality control
Where is my stuff?
˗ Materials & WIP: reduce loss of material and WIP due to
expiration
˗ Assemblies: proactively streamline production
˗ Tools: save downtime due to loss or misplaced of tools
Maintain full digital history of materials and parts
˗ Quality control
˗ Traceability
˗ Auditability
1919 Argosy Confidential & Proprietary
Dramatic Inspection gains during past 50 years
Today – Automated, high speed,
noncontact measurement
Mid 20th century – 100% Manual
measurement
Fan blade contour measured with robotic laser
line scanning
20 Argosy Confidential & Proprietary
So why do we still inspect AFP layups like this?
A350 XWB Spar Layup
Inspection at GKN
NASA 5.5m Cryo Tank Layup
Inspection at Boeing
21 Argosy Confidential & Proprietary
Argosy Confidential & Proprietary22
Automatic Fiber Placement
23 Argosy Confidential & Proprietary
AFP for NASA Cryotank
24 Argosy Confidential & Proprietary
Manual Inspection of NASA Cryotank
AFP without Machine Vision, Flaw Detection
is like the blind leading the blind
26
On Tool Defect Sensor Suite
Argosy Confidential & Proprietary
Automated Ply Inspection &
Dynamic Augmentation
Robotic scan of
demonstration article
Layup flaws detected and displayed
against programmed path
27 Argosy Confidential & Proprietary
Argosy Confidential & Proprietary28
Laser Inspection Systems
Argosy Confidential & Proprietary29
Automatic Assembly Processes
Argosy Confidential & Proprietary30
Embedded Sensors and Smart Composites
RFID Tracking Sensor
Embedded Piezo Sensors for
Load Fatigue and Performance Analysis
“We have to tame the complex so users feel powerful”*
Real-time visibility of production assets is fundamental to sustainable
cost reductions and quality control
- No contractor in the aerostructures industrial base will be
untouched by the need for this competence
We have made dramatic improvements in digital inspection over the
past fifty years
- But we still visually inspect the most advanced fabrication
procedure in composites – AFP
- We must leverage sensor suites to capture the location of
defects and harmonize the manufacturing process and the
material system
Remarks & Observations
31
*The Mission Statement of MAYA
Argosy Confidential & Proprietary
Intersecting the Future:
Supply Chain
Argosy Confidential & Proprietary32
Argosy Cutting / Kitting Concept
Argosy Confidential & Proprietary33
Customer Nest Design
Argosy Nest Design- Verification of
material utilization / final nest design
Option IVMI Material
Option IINo existing
VMI
Cold Storage for finished kits
JIT shop floor delivery
Argosy GerberCutting
Mass Production
Argosy Confidential & Proprietary34
Leveraging RF-ID technology to provide real-time,
accurate information kits and rolls in the freezer
Intersecting the Future: Supply Chain
Argosy Confidential & Proprietary35
Automatically tracking inventory and kits on the production
floor further increases productivity and reduces waste
Intersecting the Future: Supply Chain
Argosy Confidential & Proprietary36
Mobility Platforms (tablets, smartphones) and “Wearable”
Technology replace paper forms, barcode scanners and enable
real-time reporting, collaboration (Chat) and immediate action
Intersecting the Future: Supply Chain
Argosy Confidential & Proprietary37
Visualized WIP reporting
Intersecting the Future: Supply Chain
Argosy Confidential & Proprietary38
Complete visibility in real time enables corrective action
and consideration of multiple factors
Intersecting the Future: Supply Chain
Conclusions:
- Strong long-term growth – airplanes and composites
- Industrialization of composites – automotive model
- Digital technology – the internet of things
- Continued globalization
- Indigenous programs – the world is no longer Boeing / Airbus centric
- Supply chain searching for solutions
- Argosy is focused on optimizing its “space” in the market with value driven solutions
Questions
Argosy Confidential & Proprietary39
Conclusions / Questions
Avner Ben-Bassat: “Improved Visibility on the Production Floor Pushes the Productivity Envelope,” 2014
Boeing: “Current Market Outlook,” 2015
Dr. Leslie Cohen: “Design for Affordability,” 2014
Dr. Leslie Cohen: “The Digital Journey Continues,” 2015
Goldman Sachs: “Global: Aerospace + Defense,” June 24, 2014
Goldman Sachs: “The GS Commercial Aerospace Materials Series: Carbon Fiber Composites,” September, 2014
Lucintel: “The Global Prepreg Market 2013-2018 Trends, Forecasts, and Opportunity Analysis,” 2013
Porsche Consulting: “The New Value Chain – Greater Efficiency in the Aviation Industry,” 2013
Visiongain: “Aerospace Composite Market Forecast 2014-2024,” 2014
Argosy Confidential & Proprietary40
Acknowledgements
Mr. Paul Marks founded Argosy in 1988, and it is now the leading supplier of
advanced composite materials and supplies to the aerospace and composites
industries throughout Asia. With headquarters in New York and facilities located
throughout Asia and Europe, the company manufactures aluminum honeycomb
products in China for export to global markets in a joint venture with Xian
Aircraft. Argosy distributes advanced composite materials and blends aerospace
coatings. Argosy also provides comprehensive logistics services worldwide.
Mr. Marks is chairman of the boards of Argosy International Inc. and its global
subsidiaries as well as Argosy’s joint venture, Argosy XAC Composite Materials
Ltd., and a member of the board of directors of Argosy Fung Lee Industrial
Company, Ltd. Mr. Marks is also a leading member of the American Chamber of
Commerce, Shanghai where he is Co-Chairperson of the Chamber's Export
Compliance Working Group. He is a member of SAMPE (Society for the
Advancement of Material and Process Engineering) and on the board of SAMPE
China. Mr. Marks is a founding member and frequently serves as a session
chairman at the International Forum on Composite Material Applications for
Large Commercial Aircraft sponsored by the Chinese Society of Aeronautics and
Astronautics. Mr. Marks is also a trustee of Bates College, a coeducational,
nationally ranked and recognized college of the liberal arts and sciences in
Lewiston, Maine.
Mr. Marks did graduate work in Asian studies at Columbia University, National
Taiwan Political University, and Chinese language studies at Beijing Foreign
Language Institute and National Taiwan Normal University. His undergraduate
degree is in Chinese history from Bates College. Paul is fluent in Chinese
(Mandarin), and he currently resides with his family in Shanghai.
41 Argosy Confidential & Proprietary
Paul Marks – Chairman and CEO, Argosy International Inc.