5. Manufacturing Processes
Raw Material Equipment Segments
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Harness Sheet Metal Machining Tubing Composite
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Sub-assembly Segments Fuselage
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Painting System Installation and Tests Flight Preparation
DELIVERY
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6. Embraer Units
São Paulo State
Unit – Gaviao Peixoto
Unit – Eugênio de Melo
Brazil
Brazil Unit – Botucatú
Unit – Faria Lima
7. Embraer Units: Faria Lima
Located in São José dos Campos, São Paulo State.
Designs and manufactures aircraft for the commercial,
defense and corporate markets and provides after-sales support.
Floor space: 296,191 m²
Employees at Faria Lima: 10,882
8. Embraer Units: Faria Lima (cont.)
Milling Sheet Metal Shop
Composite Material Digital Manufacturing
9. Embraer Units: Faria Lima (cont.)
Structural Assembly Fuselage Junction
Painting Final Assembly
10. Embraer Units: Eugênio de Melo
Located in Eugênio de Melo, a district of São José dos Campos
This unit has a total area of 343,400 m², of which 54,607 m² are industrial buildings used in the development
and manufacturing of tooling equipment and piping, as well as for performing welding, milling and wire
looming operations.
Number of employees at Eugênio de Melo: 1,595
12. Embraer Units: Gavião Peixoto
Located in Gavião Peixoto, São Paulo State.
Manufacturing facility that will host the final assembly activities of the Company´s executive and defense
aircraft, as well as a runway for test flights.
Floor Space: 53,979 m²
Number of employees: 1,348 Start-up of operations in October 2001
15. Embraer Units: Botucatu
Embraer – Botucatu
The Indústria Aeronáutica Neiva manufacturing activities have been taken over by EMBRAER – Botucatu Unit,
which was incorporated on July 1, 2006. The following activities are performed at the Botucatu Unit: Ipanema
aircraft production, manufacture of parts and structures for the jets of the ERJ 145, EMBRAER 170/190 and Phenom
families, assembly of the Super Tucano fuselage structure, and manufacture of Ground Support Equipment tooling
and devices.
Neiva will remain responsible for Ipanema aircraft marketing activities, spare parts sales and agricultural aircraft
after-sales support.
Total Area: 122,980 m²
Floor space: 41,553 m²
Number of employees: 1,396
19. Phenom™ 100
and
Phenom™ 300
Introducing a New
Manufacturing
Process concept
20. Phenom manufacturing concept
• High performance line • Bonded Warehouse
• Maximize activities, sub-assemblies • Inventory management
• Components Assemblies in parallel with the • Planning parameter
line
• “First in First Out”
• Backflushing
• Automatic deduction from inventory based on
the Bill of Materials (BOM)
• Reduce the number of manual transactions
21. Phenom manufacturing concept
• Fixed Workcenter per employee
• Acceleration of Phenom Assembly learning curve and maturity
• Improving the quality of the product
• Multi-functional employee, dedicated in the workcenter
• Electric and mechanical assemblies done by the same employee
22. Phenom manufacturing concept
• Visual Management
• Padronization;
• Easy performance evaluation;
• Clear instructions;
• Areas of material storage marked and defined;
• Quality
• Quality with Simplified Process;
• Who does, he/she makes the quality (the operator does
and it verifies);
24. Production Ramp Up
Embraer 170/190: 70 to 78 Seats
2006 - Up to 08 ac/m
78 to 86 Seats
2007 - Up to 12 ac/m
2008 - Up to 14 ac/m
98 to 106 Seats
108 to 118 Seats
Phenom 100/300
2008 2nd Half- 15 to 20 ac/y
2009 - 120 to150 ac/y
27. ASRS System: Automated System
Automatic Storage and retrieval system for trays with integrated picking work
stations
Suitable for up to 500 pick-and-put moviments per man-hour
Heigth: up to 6 m (8m Embraer Project)
