4. Global Business
• Operations in Brazil, United States, Europe and Asia
USA France
Villepinte
Nashville
Fort Lauderdale Le Bourget China
Beijing
Portugal Harbin
Alverca
Singapore
Singapore
Brazil
Gavião Peixoto
Botucatu
São José dos Campos
Eugênio de Melo
4
5. Location – Industrial Units
Five plants
Brazil
BRAZIL
Gavião Peixoto
Botucatu Eugênio de
São Paulo State Melo
São Paulo São José dos
Campos - (2 units)
5
22. Investment – Phenom 100/300
2007 2008
JAN FEB MAR APR MAI JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAI JUN JUL AUG SEP OCT NOV DEC
5 axis Router - Composite
Fabric Cutting Machine - Composite
GPX
Router – Cabinetry Shop
Wiring Laser and Cutting Machine - Harness
Harness Test Machine
Flanging Machine - Tubing
Cabinetry Shop Extension
Veneer Room Upgrade
3 axis Ultrasound - Composite
Painting Booth - GPX
Fuselage Skin Facility - BOT
Stretch Press – BOT
Sheet Metal Router - BOT
Riveting Machine - BOT
Deburring Machine - BOT
Structural Assembly Hangar - BOT
Sheet Metal Shop Expansion - BOT
22
23. GPX Plant – Phenom 100/300 Investment
Examples
Phenom 100/300 final assembly hangar construction
Cabinetry shop extension
23
24. Investment – Phenom 100/300
2007 2008
JAN FEB MAR APR MAI JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAI JUN JUL AUG SEP OCT NOV DEC
5 axis Router - Composite
Fabric Cutting Machine - Composite
Router – Cabinetry Shop
Wiring Laser and Cutting Machine - Harness
Harness Test Machine
BOT
Flanging Machine - Tubing
Cabinetry Shop Extension
Veneer Room Upgrade
3 axis Ultrasound - Composite
Painting Booth - GPX
Fuselage Skin Facility - BOT
Stretch Press – BOT
Sheet Metal Router - BOT
Riveting Machine - BOT
Deburring Machine - BOT
Structural Assembly Hangar - BOT
Sheet Metal Shop Expansion - BOT
24
26. Investment – Phenom 100/300
2007 2008
JAN FEB MAR APR MAI JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAI JUN JUL AUG SEP OCT NOV DEC
5 axis Router - Composite
Fabric Cutting Machine - Composite
Router – Cabinetry Shop
Wiring Laser and Cutting Machine - Harness
Harness Test Machine
Flanging Machine - Tubing
Cabinetry Shop Extension
Veneer Room Upgrade SJK
3 axis Ultrasound - Composite
Painting Booth - GPX
Fuselage Skin Facility - BOT
Stretch Press – BOT
Sheet Metal Router - BOT
Riveting Machine - BOT
Deburring Machine - BOT
Structural Assembly Hangar - BOT
Sheet Metal Shop Expansion - BOT
26
34. Lean Initiative – Composite Shop
June 07 September 07
Operator’s movements per day: 49 Working cells
Walking distance: 3.900 ft (1.200 m) Operator fixed in the cell
Visual Management
34
35. Lean Initiative – Composite Shop
Hand-Layup (Daily Produced Parts )
200
150
OPs
100
50
0
MAI JUN JUL AUG SEP
35
41. Phenom 100 / 300 Final Assembly - Initial Concept
2006 Phenom program was considered as strategic to the 2006
introduction of Lean Manufacturing concept at Embraer
• High performance line
• Material Supermarket
• Visual Management
• Standardized Work
• Fixed Workcenter per employee (Multi-functional)
Phenom 100 Phenom 300
41
46. Phenom 100/300 Assembly Line
Gavião Peixoto Unit
Available area
Single Assembly Line
In Conception Completion Center
Lean Manufacturing – First enhancements
• A single line with 9 positions from 2 dedicated lines with 15 positions
• 20% cycle time reduction
• A single Production Order
• “Supermarket” concept model
46
47. VOP Strategies
• VOP re-organization
• Production Management and Investment
• Productivity Improvement
• Lean
• Automation
47
59. Planned Ramp-Up in 2006
70 to 78 Seats
Embraer 170/190:
2006 – Up to 08 A/C per month
78 to 86 Seats
2007 – Up to 12 A/C per month
2008 – Up to 14 A/C per month
98 to 106 Seats
108 to 118 Seats
Phenom 100/300
2H08 – 15 to 20 A/C per year
2009 – 120 to 155 A/C per year
59
60. Currently and Planned Production Rate
70 to 78 Seats
Embraer 170/190:
2006 – Up to 08 A/C per month
78 to 86 Seats
2007 – Up to 12 14 A/C per month
2008 – Up to 14 A/C per month
98 to 106 Seats
108 to 118 Seats
Phenom 100/300
2H08 – 15 to 20 A/C per year
2009 – 120 to 155 A/C per year
60
