Teignbridge / Sea Ray

Integration
 Executive Summary
• Inconsistent communication and lack of specifications are responsible for many of the initial problems

• Early and unacceptable quality problems with Mikado product has tainted the relationship

• The majority of the product quality and delivery issues have been resolved (supporting documentation is
available for review). It would be unfortunate to change suppliers after successfully climbing this learning curve

• UK produced product remains of a consistently high standard, with the exception of the limited cavitation
problem. We believe this issue has been remedied and can be validated to your satisfaction

• Recent trial results show Teignbridge product exhibits dramatically lower (better) variability when compared to
Hall & Stavert CNC product at PD&E and at Hatteras Yachts

• Teignbridge product delivers avg. 1-1/2 knot improvement in top-end speed along with significant annual savings
when compared with H&S. Vibration issue/non issue requires further investigation

• H&S product will require validation resources. H&S has not submitted FAIR and validation parameters

• Teignbridge will introduce improved production and process control methodologies immediately. Full box
pattern for 500DA will illustrate results. Significant capital investment over the next two years will deliver
results.

• Teignbridge satisfy 12 of the worlds premiere production boat builders including Sealine, Fairline, Ferretti,
Cranchi, Riviera, Grand Banks, Rodman etc.

• Pipeline can be dramatically reduced with improved planning by both parties

 Typical Installation
TPL vs. H&S

TPL - 4-Blade Propeller 360DA H&S - 4-Blade Propeller 360DA

 TPL Advantages
• Higher Top Speed
• Improved Fuel Economy – Increased Range
• Improved Acceleration
• Cost Savings
• Propellers Supplied: 2097 in 2003
• Propellers Supplied: 2997 in 2004
 Propellers by Month
PROPELLERS SUPPLIED BY MONTH
2003 - 2004 - 2005

400

350

300
QUANTITY PER MONTH

250

200

150

100

50

0
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
MONTH

2003 2004 2005

 Propellers Supplied
PROPELLERS SUPPLIED YEAR TO DATE
2003 - 2004 - 2005

3500

3000

2500
NUMBER YEAR TO DATE

2000

1500

1000

500

0
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
MONTH

2003 2004 2005

 Initial Design Issues
• Hub Lengths Last reported incident Dec 02, problem Non-
Standard H&S Hub Lengths and US SAE
standard references small end, rest of world works
from large end. Drawings changed. Considered
closed.

• Hub Bore Taper Last reported June 03, Mikado engineers visited
NJ warehouse to modify pipeline, machining and
inspection process changed at Mikado.
Considered closed.

• Singing Last reported November 03, trailing edge

geometry changed, visit made to Mikado January
04 to ensure compliance with drawing. Considered
closed.

• Vibration Last reported January 04, tolerances agreed with

Sea Ray/Teignbridge/Mikado. Considered
closed.
Propeller 390DA
 Singing Propellers
PORT-STRUT2
0
16.00
STBD-STRUT2
0
6.00

-4.00

-14.00

-24.00
mm/S

16.00

6.00

-4.00

-14.00

-24.00
0.02 0.04 0.06 0.08 0.10 0.12
Seconds

420DA Time plot of singing propeller Blade Rate= 20 hz Singing Frequency = 984 hz
 Singing Propeller
PORT-STRUT2 1200.000
17.558

STBD-STRUT2
10.871
800.000

400.000
RMS

0.000
1200.000
mm/S2

800.000

400.000

0.000
0.500 1.000 1.500 2.000 2.500 3.000
K Hz

420DA Frequency plot of singing propeller Blade Rate= 20 hz Singing Frequency = 984 hz
Trailing Edge
Propeller Cupping/Adjustment

Cup height – 0.060 inches (1.5mm)

 Production Issues
• On Time Delivery 2003 performance was low and unacceptable, 2004
performance has shown a dramatic improvement.
With the exception of October (computer failure) the
last 6 months were all 95% on time or above.

• Mis-marked Sizes Last reported October 03, occurred on 1 box. Re-

issued instructions to all involved. Considered
closed.

• Key Way Last reported October 03. Keyways in propellers

were correct to Sea Ray/Teignbridge tolerances.
Tolerances were changed to suit 3rd party shafts.
Considered closed.

• Blade Cracking Last reported October 03. Fully investigated by

3rd party metallurgist, agreed by all to be 1 off
incident. Considered closed.
 Current Issues
• RPM Variation Recent trials conducted by Sea Ray has proven
unequivocally that Teignbridge product is superior
to Hall and Stavert. It should also be noted that the
Teignbridge product used for the trial was a random
production sample of 10 propellers from hundreds
produced, against Hall and Stavert which were
produced for the trial, and were 10 propellers from
10 samples (see following data for trial analysis).

• Loading The 500DA with Cummins QSM-11’s have been

reported to be under loaded. Specifically, the
propellers off a 500DA in Holland, MI were
reworked numerous times to the dismay of the
customer. After numerous iterations by the
propeller shop, the engines were not loading
properly and there was a variance from port to
starboard. During the first six months of the episode
Teignbridge was unaware and the customer
has since purchased new propellers. Teignbridge
have offered the customer new propellers which he is
considering. Owner Bob Scheuerman.
 Current Issues
• Erosion First issue reported May ’04, assumed 1 off and
rectified. Since October ’04: 4 pairs of 28*35*4B
reported erosion of 238 pair supplied, 2 of the 4
pair found not to have erosion; 2 pair of 28 x
37*4B reported erosion from 62 pair supplied; 4
pairs of 30*38*5 reported erosion from 28 pair
supplied. Erosion issue traced to variations in
leading edge geometry in the finishing operation,
and uncontrolled thickness variations at the
leading edge root area.
Corrective action was taken in mid October
against the 2 issues detailed above, and also a
memo was issues to Sea Ray purchasing, and
customer service to explain the condition, lack of
impact on performance, corrective action, and
minor nature of the issue.
 Current Issues
• Erosion Cont’d Our ISO manufacturing procedures
have been changed to reflect the
corrective action for rectifying
this issue, in the following 2 ways:
1. The chord thickness at 10% and 90%
is now controlled at 0.25, 0.6 and 0.9
r/R. All Sea Ray tooling has been
checked and corrected. Inspection
procedure has been amended to include
measurement and documentation of this
thickness.
2. The importance of the leading edge
radius has been documented, training
given to finishers and inspectors, and is
now included as part of the final
inspection procedure.
Propeller Cavitation

Velocity of over 48 ft/sec

Cavitation Damage
 Propeller Section Pressure
Distribution at 30 knots 0.30 RADIUS

CHORD POSITION
-2

-1.5

-1
PRESSURE COEFFICIENT

-0.5

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0

0.5

1.5
Propeller Leading Edge
 Trial Statistics 1
PROPELLER RANGE
H&S RH = 230 RPM
STD DEV = 85.9

5000

4950

4900
ENGINE RPM

4850

4800

4750

4700

4650
1 2 3 4 5
PROPELLERS
 Trial Statistics 2
PROPELLER RANGE
H&S LH = 140 RPM
STD DEV = 53.7
5000

4950

4900

4850
ENGINE RPM

4800

4750

4700

4650

4600
1 2 3 4 5
PROPELLERS
 Trial Statistics 3
PROPELLER RANGE
TPL - RH RANGE = 110
STD DEV = 45.1

5000

4950

4900
ENGINE RPM

4850

4800

4750

4700

4650
1 2 3 4 5
PROPELLERS
 Trial Statistics 4
PROPELLER RANGE
TPL LH = 110 RPM
STD DEV = 42.8

5000

4950

4900
ENGINE RPM

4850

4800

4750

4700

4650
1 2 3 4 5
PROPELLERS
 Trial Statistics 5
PROPELLER COMPARISON
RPM VARIANCE

150

100
ENGINE RPM VARIANCE

50

TPL LH
TPL RH
0
H&S LH
1 2 3 4 5
H&S RH

-50

-100

-150
PROPELLERS
 The Future
Edge Gauges Teignbridge will procure edge gauges for all Sykes
Creek propellers, and issue to inspection to further
control the repeatability of the leading edge form.
Will apply to all Sykes Creek propellers dispatched
after 1st March 2005.

• Pipeline Inventory Issue raised that current inventory levels of

approximately 3-4 months do not allow sufficient
flexibility to make changes. Inventories have
increased over the last 6-9 months to ensure
consistent on time delivery, and allow for
inaccuracies in forecasting. No previous efforts have
been made to attempt to reduce inventories.
Following preliminary Inventory Management
Document was prepared in March 2004, outlining
some suggested ‘rules’ for forecasting and inventory
management, no further communication was
received – we would welcome your thoughts and
ideas.

• Water Test Adequate inventory exists to complete a 50/100 hour

water test, if a suitable boat is available.
 The Future
• Full Box Patterns Preliminary tests on a similar size propeller
propeller show potential for massive accuracy
improvement, reduction in local pitch variation of
50-70% have been observed. We will move to full
box patterns for all Sykes Creek 4-blade propellers.

• CNC Propellers Trial Teignbridge CNC propellers development

work is underway for five-blade production
propellers for Cranchi Yachts
Inventory Management
 Full Box Pattern

Full Box Patterns for 28 x 36 4-Blade Aquafoil

Assembled Mold
CNC Propellers
Custom Propellers
• Hatteras 68C
• Michigan CX-700
– 2318/2334 97% Load
– Speed 33.9 knots
– Failed Vibration Test
• Teignbridge Custom
– 2365/2379 93% Load
– Speed 33.6 knots
– Passed Vibration Test
 Commitment
Assign Goals & Objectives
• Teignbridge Propellers Ltd

– Provide World Class Products

– Improve Customer Service/Aftermarket
– Reduce Cost & Improve Overall Profitability
– Improve Boat Performance
– Maintain a Database of Models & Performance
Boat Database
 Commitment Request
Assign Goals & Objectives
• Sea Ray Boats
– Conduct a Technical Review by boat & propeller p/n to reach consensus on
where specific problems are behind us or where they persist
– Assign a Contact at each Plant for Integration.
– Agree on specification and validation parameters to apply to all suppliers.
– A commitment by Sea Ray that propeller conversion will occur once Sea Ray
is satisfied our product quality/performance is equal to or better than current
supplier.
– A commitment to review underwater gear components and seek conversion
under the same rule of equal to or better than current supplier.
– Develop a working relationship with PD&E.
– Maintain a Seatrial Database.