Overview
Ninety miles southeast of St. Louis, not far from Perryville, Mo. and Chester, Ill., and with convenient access to Interstate Highway 55, Sabreliner's Perryville facility is located in a rural area at Perryville Municipal Airport.

Perryville was the company's "core" facility at the time independent investors purchased the Sabreliner Division of Rockwell International and formed Sabreliner Corporation. The operation long performed assembly, completion, and delivery of new Sabreliner aircraft, and has continuously provided after-sale OEM maintenance. That proud aircraft production heritage has strongly influenced the level of personnel training, process discipline, and quality awareness at Perryville since its inception, and has led to the development of capabilities significantly greater than typical aviation repair stations of comparable size.

Primary Capabilities and Specialties
Aircraft structural maintenance, including inspection, repair, and corrosion control

Major aircraft modifications, including service life extension and installation of special-purpose sensor, communications, and weapons systems

Manufacture of aircraft components, subassemblies, and assemblies, including CNC machining, forming and heat treating

Aircraft modification kit production and installation training

Maintenance of aircraft hydraulic, electrical, and environmental control components and systems

Avionics maintenance, installation and modifications

Aircraft interior completions, modifications and renewals

Aircraft exterior cleaning, stripping and painting

Inspection, repair and overhaul of turbine engines

Product-Specific Qualifications, Experience, and Proven Performance
U.S. Navy-designated Commercial Depot for T-2 and A-4 aircraft

Structural and flight control component overhaul and/or manufacturing for Boeing 707-derived aircraft (KC-135, E-3, E-8), F-14, EA-6B, T-37, and T-33

Component and parts manufacturing for C-5 aircraft

T53, JT12, and J60 engine inspection, repair, and overhaul

OEM production, maintenance, modification and configuration control authority for Sabreliner series aircraft

Floor Space Under Roof

• More than 200,000 square feet at main site (Perryville Municipal Airport)
• 8,000 square feet at a nearby manufacturing center (St. Mary, Mo.), with expansion pending
• Additional warehouse space leased in the City of Perryville

Machinery, Equipment, and Tools
Production tooling is routinely used to fabricate sheet metal details and overhaul complete structural assemblies at Sabreliner. Methods including brake forming, hydroforming, stretching, shrinking, stretch press forming and heat treating are available for use by an experienced team of sheet metal technicians. Equipment includes a 200-ton stretch press, a 350-ton hydro-press and shears/brakes with up to 14-foot capacity.

The machine shop has numerous mills, lathes, drills, and other specialized equipment, including a 4-axis CNC milling machine, a CNC lathe, and a CNC surface grinder. Sabreliner has developed and routinely utilizes the capability to perform direct digital computer-to-CNC programming for machined parts.

Blasting and cleaning is accomplished in-house with plastic bead media, glass bead media, ultrasonic cleaners and aqueous water wash systems.

Perryville has heat treating capability for aluminum parts, and also performs stress relieving at up to 2,000 degrees Fahrenheit. Welding capabilities are in accordance with applicable AMS and military standards and include GTAW as well as GMAW.

A complete electrical wire harness shop is available for refurbishment or for manufacture of new wire harness runs.

Perryville has in-house equipment and facilities for the performance of Non-Destructive Inspection (NDI) by the liquid penetrant, magnetic particle, eddy current and ultrasonic processes. Operator certification and NDI inspection methods are in accordance with relevant ASTM and military specifications and standards.

Two hangars are dedicated to aircraft/component stripping, priming, and painting, with adequate lighting, monitoring of temperature and humidity, a dedicated explosion/flame-proof chemical mixing area, maximum use of environmentally safe products and conformance to all applicable regulations and NFPA 410.

The Perryville engine shop contains general shop machinery and special equipment such as fuel flow benches and dynamic balancers, and all special tools required to service the engines maintained here. A nearby modern, computer-controlled engine test cell performs tests using the Howell Instrument Co. AEDATS® system for collection and analysis of engine performance data.

Other shops at Perryville specialize in hydraulics and landing gear, accessory overhaul, avionics and instrument repair, tubing and hose manufacture, composites and vacuum forming, window manufacture, and interior woodwork, cabinetry, and upholstery.

Personnel
Sabreliner's management and production organization is both extremely deep and highly experienced. Due in part to its pleasant, rural location, and a lack of nearby competing industry or employers, the Perryville plant historically has had a very low turnover rate. The company has been very successful in hiring employees who have been in aviation-related specialties with the U.S. military services and want to settle permanently in Missouri. There is ample opportunity to provide thorough training and education to all professional, supervisory and direct labor personnel, and the company takes advantage of that. Most of the employees who are trained by the company remain there and build on their training; there is no need to continuously provide introductory training to a "migratory" work force of contract employees.

All of these technicians are covered under a collective bargaining agreement with the Teamsters Union. Many have in excess of 20 years of aviation industry experience and many also hold FAA Airframe and/or Powerplant licenses. The result is a skilled workforce that takes pride in doing the job right.

Government Property Control System
The property control system at Perryville is periodically reviewed and approved by Defense Contract Management Command St. Louis. The most recent property system analysis was conducted in 2000, and approval reported on 9/10/00.

Averaging recent monthly reports, the value of Government property stored at Perryville is approximately $11 million, with peak values approaching $20 million. Material Control personnel there take pride that annual physical inventory audits have found variances of only .001 per cent or less. Based on that admirable record, the Government recently extended the time between audits from one year to two.

Physical Protection of Government Property
Government and customer property at Perryville is protected by multiple levels of security provisions, which include a full perimeter fence, guards, locks on building doors, and locked, fenced cribs within the buildings. There has never been an unlawful entry reported.

Purchasing System
Procurement for Perryville operations is performed by Sabreliner's centralized Purchasing Department in St. Louis. The purchasing system and procedures are periodically reviewed and approved by Defense Contract Management Command St. Louis.

Environmental Compliance
The Perryville facility operates in compliance with all Federal, state, and local environmental requirements. An approved Integrated Environmental Response Plan that meets these requirements is in place at Perryville. The Oil Pollution Prevention Regulations, the Resource Conservation and Recovery Act (RCRA) Regulations, and the Occupational Safety and Health Administration (OSHA) Regulations are among the major Federal regulations with which the facility complies.

The State of Missouri recognized this facility's superior performance in the area of environmental protection by awarding it the state's Pollution Prevention Award for the year 2000, yet another reason for the pride the company and its technicians have in the work done at the facility.

Flight Operations Procedures
Perryville operations involving Government aircraft are controlled by the Sabreliner Government Flight Operations Manual, written to comply fully with DLAM 8210.1 (NAVAIRINST 3710.1c). The manual and all relevant procedures are periodically reviewed and approved by the Government Flight Representative assigned for current contracts.