Rolls-Royce Holdings plc Annual Report 2016 BUSINESS REVIEW
progress across all key engineering
programmes in 2016. The Trent 1000 TEN
engine undertook its first test flight in
March and received its European Aviation
Safety Agency (EASA) certification on 11 July.
The Trent 1000 TEN will power all variants of
the Boeing 787 Dreamliner family and will
power the first flight of the 787-10 in 2017.
In November, the latest version of the Trent
XWB, the higher thrust -97 engine,
successfully powered the first flight of the
Airbus A350-1000 in Toulouse. The Trent
7000 engine, which will exclusively power
the Airbus A330neo, undertook ground
testing for the first time and we started
assembly of the first flight test engines.
In respect of future technologies, the
Advance3 large engine demonstrator is
proceeding well. The engine will test the
new core architecture for future engine
families and other key technologies such
as lean burn combustion, ceramic matrix
composites (CMC), CastBond (specialist
turbine manufacturing) plus additive layer
manufacturing (or 3D printing). It is currently
in development at our Bristol, UK, facility with
all core modules advancing well.
In September, we successfully ran the
world’s most powerful aerospace gearbox
for the first time under the joint venture
Aerospace Transmission Technologies (ATT).
The gearbox is designed to reach up to
100,000 horsepower and is a significant step
in the development of the new UltraFan
engine technology.
Supporting our commitment to research
and development, we also announced a
US$30m expansion into a new facility in
Cypress, California, that will be dedicated
to research and development of ceramic
matrix composite materials and processes
for use in next generation aircraft
engine components.
Investing in new aerospace supply chain
capabilities to help drive operational
excellence
In January 2016, we announced plans to
invest more than £30m at our site in
Washington, Tyne & Wear, UK, creating a
new facility to manufacture a range of
aerospace discs for in-service engines. The
new facility is expected to be fully
operational in 2018 and will have the
capacity to manufacture well over 1,500 fan
and turbine discs a year for use in a wide
range of existing engines.
The construction of a £50m extension
to our wide-chord fan blade facility in
Barnoldswick, UK, started in December.
The expanded facility will be able to
manufacture 6,000 large Trent fan blades
a year, almost twice its current capacity.
We also announced the creation of a
centre of excellence in structures
& transmissions at the same site. The new
centre, supported by £20m of investment,
will manufacture many of the complex
structures that feature in all Rolls-Royce
aero engines.
Good progress strengthening our aerospace
aftermarket service offering
We have continued to invest in our service
capabilities to support our customers with
state-of-the-art facilities and relevant
products and services, particularly within
our portfolio of TotalCare offerings.
During the year, we completed changes to
three Approved Maintenance Centre (AMC)
joint ventures. This included investing
£154m to increase our stake in both Hong
Kong Aero Engine Services Limited (HAESL)
and Singapore Aero Engine Services Pte
Limited (SAESL) to 50%. These AMCs support
our strategy to offer a competitive, capable
and flexible Trent service network to meet
the changing needs of customers across the
lifecycle of engines and to support the
growing Trent engine fleet.
Additionally, we announced further details
of a new AMC in Abu Dhabi with Mubadala
Development Company, the emirate-based
investment and development organisation.
This purpose-built facility will carry out
work on the Trent XWB.
We also announced that we are further
expanding our global network of Authorised
Service Centres (ASC) for business aviation
aircraft under our CorporateCare® service
provision for customers. Rolls-Royce now
has 62 ASCs in place with key maintenance
providers worldwide.
Following the launch of SelectCare in 2016,
we secured our first agreement for Trent
800 engines as part of a wide-ranging deal
with Delta Airlines.
Civil Aerospace outlook
On a constant currency basis, our Civil
Aerospace business should deliver modest
growth in revenue and profit in 2017,
supported by large engine aftermarket
growth, further lifecycle cost reductions and
a higher level of R&D capitalisation. Business
jet demand is expected to weaken further,
as will the demand for aftermarket services
to support Rolls-Royce powered regional
aircraft. After a better year for trading cash
flow in 2016, we now expect this to be
broadly unchanged year-on-year reflecting
higher volumes of cash-loss-making engines
offsetting the positive effects of higher
aftermarket cash revenues.
We expect the TotalCare net asset to peak in
the next 12 months at between £2.5bn and
£2.7bn, reflecting further targeted lifecycle
cost improvements and other timing
differences between cost and cash.
Positive market developments continue to
drive long-term growth in Civil Aerospace
The long-term positive market trends for
our leading power and propulsion systems
remain unchanged despite some near-term
uncertainties in Civil Aerospace that continue
to impact business jet engine production
volumes and service activity on older large
engines. The long-term trends driving
demand for growth in large passenger
aircraft, business jets, power systems and
maritime activity remain strong; in particular
a growing aspirational and mobile
middle-class, particularly in Asia, and
globalisation in business, trade and tourism.
While recent political and economic
developments have added some uncertainty
to near-term utilisation, we continue to
expect that strong widebody airframe
demand – driven by the need for newer,
more fuel-efficient aircraft – should provide
resilience to manufacturing schedules over
the next few years as the industry
undergoes a strong replacement cycle.
New airframe growth and transitions are
in line with expectations
Preparations for the transition of the Airbus
A330ceo to A330neo models are also
progressing well and once the transition is
completed we will benefit from an exclusive
position with the new Trent 7000 on
the A330neo.
The roll-out of new engines, including the
Trent XWB for the highly successful Airbus
A350 family, will significantly grow our
market share and the installed base of new
engines that will deliver strong aftermarket
revenues for decades to come.
STRATEGIC REPORT