KTM Solutions, Inc.

Company Overview – GeneralPrepared for

SBIOI - Charleston, SCApril 22, 2010

Rob McDaris – Senior Engineer/Charleston Business Development

Company Overview

KTM Solutions, Inc enables aerospace, automotive, and machine design

companies to successfully complete urgent mechanical and structural design

projects without overwhelming or enlarging existing staff.

Our seasoned engineering staff averages 20 years of engineering

experience!

On Demand Engineering® - Engineering and management resources available when you need them

On Demand Engineering® means service starts when we receive your call

On Demand

• Mechanical Design / Structural Analysis

• Aircraft / Automotive / Product Development• 2D Drawing / 3D Modeling • Classical Static Strength• Durability and Damage Tolerance (DADT)• Finite Element Modeling• Reverse engineering• FAA Certification Process

• Project Management / Systems Engineering

• Experienced Workforce / Ample Capacity– 24 full time/part time– 5 registered engineers– Average experience 20 years – Experience ranges from conveyor

design to aircraft high lift systems

CATIA SWORK Other ANSYS Classical NAST D&DT Other Aircraft AutoMach DSN

8* BSME 41 MD X (1) . - L H19 ASMET 18 TD X X (1). - H H20 - 1 EA X X (1). - - L21 - 1 EA X X (1). - - L1* BSME 25 MD X X X H L L2* BSME 10 MD X X (1)(2)(5) X H L L3 BSME 6 SA X X X H L -4 MSAE 21 SA X X (3)(9) H - -5 BSME 7 MD X X (4)(5) X X H - H6 MSME 25 SA X X (6)(7) H - -7 BSME** 33 MD X (1)(2) H - -22 MSAE 19 MD X X X X H - -10 ASMET 7 EA X X (1) . L M H14 - 2 EA X X (1). L L L15 - 2 EA X X (1). L L L17 ASMET 4 TD X X (1). L L M16* PHDEM 28 SA X (10).

ClassHighest Degree

Years Exp

Engineer Number

Design Stress Industry Experience

KTM Solutions Depth Chart

Capacity - On Demand

Our Team

Corporate Governance:– April 2005, KTM Solutions, Inc. – A South Carolina

Corporation (Woman Owned Small Business)– Ginger A. Kumler – CEO, Business Manager– Paul V. Kumler P.E. – President, Chief Engineer

Certifications/Credentials:– Registered Engineering Company, South Carolina– Licensed Professional Engineering, South Carolina– Senior Engineering Management Experience with

Fortune 50 Aircraft Companies

Facilities:– 4000 ft2 Greenville, SC (Headquarters)– 2000 ft2 North Charleston, SC (Planned 3 QTR 2010)

Aerospace Experienced Engineering Staff –

Senior KTM engineers and management were trained and developed by large aersopace companies (Boeing, Lockheed Martin, Raytheon and USAF)

Structural/Mechanical and Analysis –

Primary structures (wing, body, empennage) design and analysis; electrical rack/packaging; and secondary structural design; aircraft modification

Key Clients –

Aircraft OEM’sAircraft Tier I SuppliersAircraft Modification Facilities

Aerospace

Aircraft structural design and analysis is historically 60% of our business

Key Capabilities

– Primary and secondary structural design and analysis

• 3D Modeling (CATIAv5/SolidWorks)• Manufacturing Drawings• Static strength• Durability and Damage Tolerance• FAA Certification Planning• Finite Element Analysis (NASTRAN/FEMAP)

– Mechanical systems / high lift devices• Control surfaces and systems• Landing gear• Hydraulic components

– Modification and repair of legacy aircraft• Shipside support• Materials Review Board (MRB)• Aircraft upgrades

– Systems Engineering and Project Management

Recently completed wing upgrade – Business Jet OEM (Kansas)

Aircraft Primary Structures

• Major Assembly Fixtures– Locating Jigs– Holding Fixtures– Large platforms– Assembly fixtures– Welding fixtures– Retrofit jigs– Pneumatic and electrical systems

• Hand Tool Development and Improvement– Modified hand tools– Small assembly fixtures, holding

fixtures– Specialty tools

Tool Engineering

• Material Properties Analysis– Forensic material analysis including

alloy identification and heat treat/hardening

– Failure investigations– Part usage and environment

considerations– Improvement recommendations

• Geometric Analysis and Assembly Study– Dimensional analysis of manufactured

parts– Part to part relationship and tolerance

study– Manufacturing drawings developed from

3D design

Reverse Engineering

• Mechanical and Structural Systems Design– Packaging of mechanical

components– Structural integrity through

defined operating spectrum– Component selection– Design refinement using

existing products

• Customer Certification and Compliance– Support of European Union

(CE) certification– Matching existing interfaces

New Development

• New conveyor systems– Materials and component selection

based on industry standards– Maximize use of “off the shelf

hardware and equipment (lowers cost)

– Custom design for each unique application (physical parameters, temperature, operational characteristics)

• Reverse engineering for component obsolescence– Match existing equipment and

interfaces– Meet or extend life cycle goals

Conveyor Related Systems

• Material Processing Machinery– Systems designed to process raw

materials into product– Off the shelf components matched to

designed hardware– Complete systems architecture– Simplified operator interfaces and

safety devices– Designed to meet life cycle and

operational goals

• Maintenance and Repair– Reverse engineering of individual

components to extend machine life– Simulation and analysis of

operational problems

Machine Design

• Design and Analysis of Box Girder Beams– Double beam girders– Lower mount single girders– Torsional girder beams

• Common analysis packages– FEM/FEA– Hand structural analysis using

conventional methods– Optimization of design for

lowest weight (material costs)

70 feet

10 ton working load

Heavy Lifting Systems

• Program Controls and Plans– Requirements accountability– Requirements Verification– Risk Management– Design progress reviews– Integrated Master Schedules– Contract/SOW/Spec integration

• Integrated Product Teams– All stakeholders– Concurrent design process

Systems Engineering – KTM PRO 45 (based on MIL-STD-499B)

Systems Engineering

ConceptDefinition

RQMT’sAllocation

BasicDesign

DetailDesign

SystemTest

Fab

ElementTest

I&CO

Production

Inputs:

• RFP• SOW

Tasks:

• Conduct Systems Studies• Identify desired capabilities

and functional requirements• Develop Operational

Scenarios• Conduct System Trades• Prepare Systems

Specification• Prepare Proposal

Outputs:

• Operational Concept• Systems Specification• Systems Trade Study

Reports• Preliminary Development

Plans• Proposal• Systems Requirements

Review Agenda/Data Package

Inputs:

• SOW• CDRL• Proposal• Top Level Spec• Results of Concept Definition• Preliminary Plans

Tasks:

• Systems Trades• Requirements Allocation• Make/Buy• Initiate Development of

• Part 1 ICDs• Subcontract SPEC, SOW, SDRL

Outputs:

• Initial• Part 1 ICD’s• Subcontractor Packages

• Trade Study Reports• Final Plans• SDR Package

Inputs:

• Initial• Part 1 ICD’s• Subcontractor

Packages• Plans• Schedules

Outputs:

• Initial• Part 1 ICD’s• Subcontractor Packages

• Trade Study Reports• Final Plans• SDR Package

Tasks:

• Refine Requirements Allocations• Finalize

• Part 1 ICD’s and Specs• Subcontractor Packages

• Conduct Design Trades/Analysis• Develop detail design approach• Technical performance measurement

Inputs:

• Part 1 Specification and Interface Baseline

• Basic Design Approach

Outputs:

• Released Engineering

• Final Part II ICD’s• Initail product

Fabrication Specifications

• CDR Data Package

Tasks:

• Complete Detail Design• Generate Part II ICD’s• Develop initial

production Fabrication specifications

• Technical Performance Measurement

• Generate detail test requirements and test procedures

Inputs:

• Formally tested hardware and software elements

• Integrated and checked out system

Tasks:

• Integrated systems tests

• Systems fixes• Update Design

Documentation to reflect as built/as qualified configuration

• Prepare final test documentation

Outputs:

• FCA/PCA Data Packages• Final Documentation

• Specs• Engineering• O&M Manuals

• Test Plans, Procedures, reports

• Contract Compliance Documents

SRR SDR PDR CDR FCA/PCA

ConceptDefinition

RQMT’sAllocation

BasicDesign

DetailDesign

SystemTest

Fab

ElementTest

I&CO

Production

Inputs:

• RFP• SOW

Tasks:

• Conduct Systems Studies• Identify desired capabilities

and functional requirements• Develop Operational

Scenarios• Conduct System Trades• Prepare Systems

Specification• Prepare Proposal

Outputs:

• Operational Concept• Systems Specification• Systems Trade Study

Reports• Preliminary Development

Plans• Proposal• Systems Requirements

Review Agenda/Data Package

Inputs:

• SOW• CDRL• Proposal• Top Level Spec• Results of Concept Definition• Preliminary Plans

Tasks:

• Systems Trades• Requirements Allocation• Make/Buy• Initiate Development of

• Part 1 ICDs• Subcontract SPEC, SOW, SDRL

Outputs:

• Initial• Part 1 ICD’s• Subcontractor Packages

• Trade Study Reports• Final Plans• SDR Package

Inputs:

• Initial• Part 1 ICD’s• Subcontractor

Packages• Plans• Schedules

Outputs:

• Initial• Part 1 ICD’s• Subcontractor Packages

• Trade Study Reports• Final Plans• SDR Package

Tasks:

• Refine Requirements Allocations• Finalize

• Part 1 ICD’s and Specs• Subcontractor Packages

• Conduct Design Trades/Analysis• Develop detail design approach• Technical performance measurement

Inputs:

• Part 1 Specification and Interface Baseline

• Basic Design Approach

Outputs:

• Released Engineering

• Final Part II ICD’s• Initail product

Fabrication Specifications

• CDR Data Package

Tasks:

• Complete Detail Design• Generate Part II ICD’s• Develop initial

production Fabrication specifications

• Technical Performance Measurement

• Generate detail test requirements and test procedures

Inputs:

• Formally tested hardware and software elements

• Integrated and checked out system

Tasks:

• Integrated systems tests

• Systems fixes• Update Design

Documentation to reflect as built/as qualified configuration

• Prepare final test documentation

Outputs:

• FCA/PCA Data Packages• Final Documentation

• Specs• Engineering• O&M Manuals

• Test Plans, Procedures, reports

• Contract Compliance Documents

SRR SDR PDR CDR FCA/PCA

TBD

TBD

TBD

TBD

Verf.Procedure

InspWarning placards shall be installed on each assembly that is powered by multiple power sources.

Power455500

Run Diagnostics to Verify.

DemoReliability and performance requirements shall be met with an inlet water temperature of +70 deg F.

Unit Cooling448000

Run Diagnostics to Verify.

TestAll Ship Safety/Self Protect equipment shall be capable of operation over the ambient air temperature range of +40 deg to +104 deg F.

Air Temperature447600

Use Mechanical Analysis Tools to prove.

AnalThe equipment design as installed on the ship shall meet all performance requirements when subjected to the combined conditions of pitch, roll, and yaw listed in Table 3.4.1.1-1.

Ship's Motion447500

Verification results

Verf.Meth.

RequirementSection TitleSEQ #

TBD

TBD

TBD

TBD

Verf.Procedure

InspWarning placards shall be installed on each assembly that is powered by multiple power sources.

Power455500

Run Diagnostics to Verify.

DemoReliability and performance requirements shall be met with an inlet water temperature of +70 deg F.

Unit Cooling448000

Run Diagnostics to Verify.

TestAll Ship Safety/Self Protect equipment shall be capable of operation over the ambient air temperature range of +40 deg to +104 deg F.

Air Temperature447600

Use Mechanical Analysis Tools to prove.

AnalThe equipment design as installed on the ship shall meet all performance requirements when subjected to the combined conditions of pitch, roll, and yaw listed in Table 3.4.1.1-1.

Ship's Motion447500

Verification results

Verf.Meth.

RequirementSection TitleSEQ #

Reqmt Number

Authority SOW Number

Requirement Owner Method of Verification

Due Date Cross Reference

Status Risk Level Closure Evidence

1 CONT 2.1 06151A10 Provide structural attachments for supporting 10 pound LRU on forward bulkhead at sta 360, WL 200, BL 30R within +/- 2 inches

Jones Visual 1-May-09 Spec 24.3 Open Low Drawing Release

2 CONT 2.1 06151A11 Provide structural pentrations through forward bulkhead at sta 360, WL 200, BL 30R within +/- 2 inches to accommodate 6 inch dia wire bundle.

Culpepper Visual 1-Apr-07 Spec 24.3 Open Med Drawing Release

3 CONT 2.6 06151B31 Develop systems installation that will accomdoate RCA 13789A24 Radio without degradtion of performance in existing radio range. If performance is degraded, client must decide whether to complete installation

Koslowski Test 1-Apr-07 Spec 54.3 Open Med Functional test and supporting analysis

Requirement Accountability Matrix

I nsignificant Minor Moderate Major Catastrophic

1 2 3 4 5

5Almost Certain M H H E E

4Likely M M H H E

3Possible L M M H E

2Unlikely L M M H H

1Rare L L M M H

 

High or Extreme risks must be reported to Senior Management and require detailed treatment plans to reduce the risk to Low or Medium.

E – Extreme risk – detailed action plan required

H - High risk – needs senior management attention

M – Medium risk – specify management responsibility

L – Low risk – manage by routine procedures

Lik

elih

ood

Consequence

KTM Quality Management System –

Our processes are designed to provide consistency of product. Processes (PRO) are authorized by Policy (POL) and audited regularly. Instructions (INSTR) are released for client unique requirements

They include topics such as:– Document Control– Quality Assurance– Analysis Methods– Safety Analysis– Bidding– Technical Services– Contracts– Consulting Services Design – Technical Reviews ISO 9001:2008 and AS9100 compliant

• Mechanical Engineering / Structural Analysis

– Prototype and Production Design – Static Analysis– Finite Element Modeling– Durability and Damage Tolerance

(DADT)– 3D Simulations– Digital Pre-Assembly– Aircraft Certification Compliance– Systems Engineering (MIL-STD

Compliant)FEA / 3D Models / Simulations / Drawings

Aerospace | Automotive | Machine Design | Product Development

KTM Solutions is a Woman Owned Small Business

Overall Summary

• Postal ServiceGinger A. Kumler – CEO Paul V. Kumler, P.E. – President1095 Thousand Oaks Blvd, Suite 201 1095 Thousand Oaks Blvd, Suite 201Greenville, SC 29607 Greenville, SC 29607

Rob McDaris – Business Development1095 Thousand Oaks Blvd, Suite 201Greenville, SC 29607

• E-Mailinfo@ktmsolutions.com

• Telephone864-297-6600

• Facsimile864-297-5757

Contact Information

Thank You!

FEA / 3D Models / Simulations / Drawings