Tulsa World: First Wave makes splash

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First Wave makes splash
Aerospace company known worldwide

Tom Powell cleans a gear door for a DC-10 jet Wednesday at First Wave in Bristow. MIKE SIMONS/Tulsa World

By D.R. STEWART World Staff Writer
Published: 8/22/2009 2:22 AM
Last Modified: 8/22/2009 4:13 AM

Flying under the radar of publicity that attaches to more established companies, First Wave MRO Inc. is a northeastern Oklahoma aerospace company earning a worldwide reputation as a first class manufacturer and repair organization.

The company is like the classic Western character of few words whose actions speak volumes.

"We've always kept a low profile," said CEO Ben Clark. "But we do work in China, India, Turkey, Belgium, Canada, Mexico and Brazil. We are about half-and-half domestic and international sales."

With corporate offices and its state-of-the-art 226,000-square-foot manufacturing plant on the western edge of Bristow, surrounded by rolling ranchland 40 miles down the Turner Turnpike from Tulsa, First Wave belies its industry stature.

Its customers include American Airlines' Tulsa Maintenance & Engineering Center, which also provides services to First Wave.

Internationally, its customers include world market leaders such as Embraer of Brazil, British Airways, China Southern Airlines, the New Zealand Air Force and Qantas Airways of Australia.

Privately held and family owned, First Wave was founded in Tulsa by Ben Clark's father, Edward D. Clark Jr., in 1992. The senior Clark, a Muskogee native, is First Wave's president, and he started the business by acquiring the surplus aircraft parts inventory of American Airlines.

Originally, First Wave Aviation bought and sold spare parts for Boeing and McDonnell Douglas aircraft. Today, it has one of the largest inventories of rotable (repairable) and expendable aviation parts in the world.

With parts inventories in Oklahoma and Brazil, First Wave Aviation serves both domestic and international airlines and aerospace companies. Parts sales at the company have more than doubled since 2001, company executives said.

In 2002, Edward Clark decided to branch out, founding First Wave MRO (Manufacturing & Repair Operations) by converting a 25,000-square-foot Tulsa warehouse into a Federal Aviation Administration Repair Station.

First Wave MRO began with a modest product line of engine thrust reversers and composite repairs and a customer base primarily in Europe and Asia.

Year by year, the business grew.

"We have a real good marketing team — one of our guys just got back from China last week," Edward Clark said. "Everyone says they are able to hit price, quality and turn time, but we have to add value, too. We have completed thousands and thousands of shipments of spares and components — on time."

Satisfied customers translated into increased demand. Before long, First Wave MRO was outgrowing its Tulsa facilities.

In consultation with SpiritBank, its lender and financial consultant, the Clarks built a spacious $22 million commercial and military aircraft component repair and manufacturing facility in Bristow in 2007.

The move to Bristow was encouraged by the state of Oklahoma after the area's largest employer, Black & Decker Kwikset, moved its Bristow operations to Mexico.

SpiritBank worked with state and federal agencies to assist with the expansion and relocation and to create additional jobs, company executives said.

"We've had our bumps, but SpiritBank has been right there for us," Edward Clark said.

Mary Smith, director of SpiritBank's aerospace division, said she is impressed by First Wave's diversification.

"They have a balance between commercial and business and foreign and domestic," she said. "It's kind of like looking at an investment portfolio: You have to have a balance."

First Wave MRO's 226,000-square-foot Bristow facilities include a 300-square-foot autoclave that cures bonded components such as nose cowls, fan cowls, thrust reversers, exhaust nozzles, wing components and other structures.

A "clean room" is more than double the size of some Tulsa aerospace manufacturers. It is temperature-, humidity- and particle-controlled for composite and metal bonding.

Eight tanks holding thousands of gallons of chemicals make up the facility's Phosphoric Acid Anodizing Line.

The PAA Line is a critical process at First Wave to ensure proper bonding of aluminum alloys. Metal parts are placed on racks, which are lifted by crane and dipped into successive tanks of alkaline cleaner, water rinse, sodium dichromate and sulfuric acid, phosphoric acid, de-ionized water and a forced-air drying cycle.

"The PAA Line is where the metal meets the road," Ben Clark said. "It creates a nice microscopic etching on the metal so you get good bonding."

First Wave MRO's PAA line is set up in accordance with Boeing's specifications and is approved for use on all Boeing products, company executives said.

The facility also has FAA certification for commercial aviation component repairs as well as certification by the European Aviation Safety Agency and various original equipment manufacturers.

The Clarks established First Wave Brazil in 2004 to supply the aircraft component needs of Embraer, the Brazilian commercial and corporate aircraft manufacturer. The company now employs 250 people, and it generates business for the Bristow facility, the Clarks said.

But First Wave's global business began with American Airlines, which Ed Clark calls "the most under-appreciated company in the state."

"There are so many companies in the state — us included — that wouldn't exist without American Airlines," Clark said. "They have done things to help us and they are fantastic to work with. They can do anything. They are among the best tooling manufacturing organizations in the world."

First Wave thrives in the shadows of the Americans, NORDAMs, Spirit AeroSystems and Lufthansa Techniks. But, maybe it won't be in the shadows for long.

First Wave MRO Inc.

Business: Aerospace component manufacturing and repair.

Principals: Edward D. Clark Jr., founder and president; Ben Clark, CEO.

Established: 1992.

Divisions: Corporate offices: 23800 S. 369th West Ave., Bristow; First Wave Aviation LLC, 5440 S. 101st East Ave.; First Wave MRO, 6970 E. 38th St.; First Wave Brazil, Taubate, Brazil.

Employees: 100 in Tulsa area, 250 in Brazil.

Customers: American Airlines, British Airways, China Southern Airlines, Continental Airlines, New Zealand Air Force, Qantas Airways. United Airlines.

Source: First Wave MRO Inc.

D.R. Stewart 581-8451
don.stewart@tulsaworld.com By D.R. STEWART World Staff Writer

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	Report Comment oldnorthroad, (8/24/2009 11:24:42 AM) Nice to see a success story like this one.
	Report Comment David L Perkins Jr, tulsa (8/25/2009 9:45:49 AM) Great article. Very well written Mr. Stewart, good job. Congratulations to Messrs. Clark., and love those Tulsa jobs!

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