010© ADSE B.V. 1 New supply chains, new manufacturing techniques New aerospace education?? Jan Verbeek Amsterdam, 16 april 2010
Jan 21, 2015
2010© ADSE B.V. 1
New supply chains, new manufacturing techniques
New aerospace education??
Jan VerbeekAmsterdam, 16 april 2010
2010© ADSE B.V. 2
ADSE introduction
• Independent consulting and engineering company, founded in 1996, focused on:
– Design integration and certification– Complex system development processes, including
industrialisation and life cycle support• 80 employees and extensive network for additional services
• Active in:– Aerospace industry & Air Transport, – Defence – Infrastructure & Rail transport
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Our WorldAerospace – example projects
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• More and more people want to fly– Growth of economies in Asia, Brazil, Middle East, Africa– Global business– Leisure
• Air transport has become a commodity– Double digit growth in China, Emirates– Low cost operators in US, Europe, Asia– Global Airline Alliances– Global networks
People want to fly
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Limitations to further growth
• Cost of aircraft and services• Fuel availability• Safety• Environmental impact• Competition
– High speed trains– Video conferencing– Internet
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Challenges to aerospace suppliers
• Aerospace suppliers (OEM’s and supply chain) have to offer solutions which meet
– Increasing customer demand for innovations on aircraft• Reduced fuel burn• Alternative fuels• Improved economics• Further improved safety• Reduced environmental impact
– & Services• Sales financing• Reduced and guaranteed power by the hour cost• Residual value management • Local return through offset obligations in production
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Challenges to aerospace suppliers
• But industry also has to make profits– Reduce cost to maintain or improve margins– Control and reduce time to market– Leverage buying power – Seek economy of scale, through global sourcing
• This means– Offering real functional solutions– Reducing development and production cost– Improving the time to market capability of the supply chain– Closing gaps in the supply chain
• Capability• Cultural
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Challenges to aerospace suppliers
• So concluding: aerospace manufacturers: – Have to introduce new technologies
and
– Continuously optimize their supply chain while
– Achieving maximum process control
• They need to explore unknown territory and deploy innovations in a controlled way
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Aircraft design and technology
• Continuing trade off’s between step changes or incremental developments
• For new aircraft programs – Optimized metal or fully composite airframes, hybrid interfaces?– New power plant concepts, using new (bio-)fuels? – Blended Wing Bodies or other aerodynamic features (winglets,
slender wings)?– All electric aircraft systems?– More integrated avionics?
• ATC systems, on board systems (vehicle control and IFE)• Smart structures, built in diagnostics/health monitoring systems
– Highly modular cabin systems?
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Aircraft design and technology
• For aircraft with enough program life (now and later)– B737, A320, B777, A330, CRJ, F100? – A380, ERJ series – B787, C-Series, MJET, A350
• Continuous and/or mid life updates and retrofits?– Re-engining?– Cabin upgrades?– Cockpit upgrades?– Etc
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Production technology
• Airframe and Final Assembly – Composite manufacturing: fibre placement/RTM/thermoplastics?– Machining vs bonding vs sheet metal assembly for metal
airframes?– [Stuffed] components, smart structures?– Robot assembly, process automation (24/7 operations, paperless
factory??• Systems:
– Modular/miniaturized avionics, smart sensors?– Electric actuators, composite gears, new engine materials?
• Cabin: – Systems integration into modules (customization like in cars)?
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Process improvements
• Seamless CAE/CAD/CAM/CAI/CAT ?– Computer Aided Simulation/Analysis – 3D Digital Mock Up
• 3D Model Based Definition used in production?– No more 2D drawings
• One tool for Configuration Management during development from requirements to certification (V&V) and rest of program life cycle or connected “islands”?
• Lean/6 sigma for in process control by improved accuracy or built in tolerances in design?
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Supply chain developments
• Integrators reduce their in house manufacturing– Sell off internal 1st tiers and manufacturing plants?– Provide local return through local production?
• First parts and subassemblies, • Later also stuffed components and FAL?
• Global sourcing and extended enterprises– New 1st tier partners (ongoing consolidation)?– Global specialist 3rd and 2nd tiers?– Outsourcing to low cost countries! – Supplier development (1st and 2nd tier in delegated authority)??– Framework contracts covering critical materials like CFRP, Ti?
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Supply chain developments
• Forcing one set of company specific methods/ICT-tools on the supply chain or global standardization or islands and interfaces?
– Q? CM? Certification?– Project/program Management?– CAD?– PDM?– ERP/MES?
• Bridging capability and cultural gaps?– Supplier development and help desk function to implement the
Extended Enterprise? – Cross cultural training?
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New aerospace education?
• Businesses have to further develop the capabilities of their employees
– Develop existing people and teams– Select, train and develop new people
• Developing– Knowledge– Skills– Behavior
• Educators (from schools, universities and business) will have to develop the people needed
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New aerospace education!
• There is an increasing demand for more integrators (mix of technical, commercial, organizational, cultural)!!!
• But not at the expense of real, in depth specialists!
• People who can:– Innovate, develop and certify
• Products & Systems• Processes and organizations (Design, Production, Maintenance &
Support)
– Assure Quality throughout the supply chain • Production• Also including D&D responsibilities
– Manage businesses, department, programs and projects in a global commercial setting
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New aerospace education!
• Education therefore has to cover the following hard core Aerospace Technology subjects
– Design, development, certification of• Aircraft, airframe components• Aircraft systems• Power plant • Payload systems• Etc
– Processes & Materials – Industrial process development
• Manufacturing, assembly & test, quality, logistics processes• Design for Manufacturing & Assembly (..& RAMS)• Industrialization (from specification to deployment)
– Plants, Machines and equipment, Tooling, Process automation
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New aerospace education!
• And also cover the following Aerospace Process & Organization (both hard core and soft skill) issues
– Project and program management• Design & development, industrialization, ramp up, series
production/continuous improvement
– Financial (cost estimating, cost/schedule control, value engineering)
– Management of professionals (HR)– Work in teams (internal, international, global)
• That work together• Respect different cultures• And find ways to make things work
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New aerospace education!
• This will have an impact on basic aerospace education– Technology knowledge and project management skills are starting
points– All other aspects mentioned also need to be addressed in depth!!
• In a specific Aerospace way• But shared with/copied and translated from other industries
• There is also demand for life long learning programs – To share experiences and best practices– To deepen insights and know why– To build global communities of skilled and experienced people
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New aerospace education!!!
People that help explore unknown territory
and deploy innovations,
always in a controlled way !!