Lanner client TST discuss simulation application and benefit

T u r b i n e S u r f a c e T e c h n o l o g i e s

Simulation Application & BenefitsJoe Barker

April 2016

T u r b i n e S u r f a c e T e c h n o l o g i e s

Introduction & Overview

• Worked in Rolls-Royce Aerospace for 18 Years.

• Head of Operation & HS&E – TSTL, based in Annesley.

Presentation AimsA short presentation outlining Turbine Surface Technologies and the practical use of simulation to reduce lead time.

Agenda

• Background to the aerospace markets. • TSTL – History• Process Overview• Technology• TSTL Facility• Model Construction• Conclusions and future plans.

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Turbine Surface Technologies – Aerospace & Lead Time• Strong growth in Aerospace markets over the next

10 years. • Airbus A350 & Boeing 787 are at the start of their

product lifecycles. • Overall markets set to double inside the next 10

years. • New engines require investment in new technology. • Cash, Inventory / Lead Time is key to the ability to

invest in new technology. Rolls Royce Trent XWB on wing

Rolls Royce Gas Turbine

Airbus A350 Order Book (Feb 2016)

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Turbine Surface Technologies - History

• Joint venture company between Rolls-Royce and Chromalloy– Established August 2000

• Builds on the strengths of both parent companies– Rolls-Royce innovation of new coatings and strong market– Chromalloy proven production implementation and knowledge

• Centre of excellence specialising in coatings for gas turbine components located in the hot gas path section of the engine– Responsibility to improve the process– Generate new technology – Develop people skills to apply this technology to new products– Establishing operational best practice

• Part of the Rolls-Royce Turbine Components Supply Chain– Blades and vanes (NGVs)

Ceramic Core Manufacture

Investment Casting Machining Coating

Machining & Final

Inspection

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• Power output 10 times higher than a typical family car• Local gas temperature 200°C higher than alloy melting

point• Local gas temp ~ 1580°C• Alloy melting point ~ 1350°C

• Centrifugal force on each blade is equivalent to the weight of a heavy truck

• Life requirement is 30 000hrs• About 6 yrs at 14 hrs per day, 5 Million miles between

major services.• Coatings application has increased from 25%, now on

more than 50 % of ‘hot end’ turbine components

• Unit cost ~£1100 per blade. • One third of this is coatings cost

Technology – What do we do?

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Process Overview

EB PVDFinal Age

Heat Treatment

FPIShroud Fin HVOF

Airflow and Lab

Final Inspection

and Dispatch

Receipt and Preparation Pt Plating Heat

TreatmentAerofoil Film

Cool EDMStop-off Blade

Internal and Shroud Aluminise

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Turbine Surface Technologies – Annesley Facility• Facility opened in 2002

– 90000 sq ft operational and R&D facility• Highest ever output in 2013 - £47.8m

– Sales doubled in 4 years in response to customer demand• 2015 output £32m (230 000 parts), Forecast output in 2016 £39.6m • Currently 360 employees

Pack and Vapour Aluminising Platinum Plating Low Pressure Plasma Spray HVOF / APS EBPVD

Vacuum Heat Treatment Media Finishing Production Laboratory

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The use of simulation – Why bother?• Simulation was first considered at TST in 2012.

– Considerable time spent in outlining the model that could be used. – Overcomplicated – Scope too large.– Difficulty in obtaining data required to support model.

• Lead time reduction is a key objective for the business & customer.

• Capital investment decisions to reduce lead time require data to support the business cases.

• Operational changes can be prioritised if the impact can be understood.

• Engagement of internal teams and external stakeholders – Management of change.

• Not a substitute for Load & Capacity modelling.

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The use of simulation – Designing a model

Pt Plating Process

Blasting Masking Drying Tooling Plating Inspection

• Avoid over complication.• Set the right level of detail. Consider black boxes rather than individual processes. • Use part families – Simplified design doesn’t need to consider different part number. • Only consider headcount if this is the constraint to the process.

– Not a substitute to load & capacity modelling.• Impact of transactional processes / non-standard processes. Leaving these out will simplify the

model but may lead to inaccurate results.

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The use of simulation – Gathering dataInvolve a Balanced Team

Operational DataOperational sequence – Readily AvailableSite input / output data – readily AvailableCapacity information – Readily AvailableOverall lead time data availableAsset – Failure / recovery times - Available Headcount information – Available

Issues ExperiencedRework / Rectification / RFT? – Are they all known? Decision not to include in model. Operational times used as estimates – How do we know these are accurate?

ERP Data Available

Maintenance System

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The use of simulationBuild The Model Model built by Lanner. Validate modelAgainst existing lead time performance against different product groups. What to change if initial results don’t match reality?

ScenariosUnderstand what questions need to be answered before the model is constructed. Adapt list during build phase.

ResultsResults show sensitivities of changes rather than an absolute prediction of lead time.

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The Benefits

Flow Description Old SLA New SLA Example ComponentsB01 Aluminise 14 11 BR710, 535E4, Adour, TayB02 Pt., Aluminsie, HVOF 21 18 Fleet HPTBB03 Pt., Aluminsie, HVOF 28 21 T900 IPTB, T1000 IPTB, XWB IPTBB05 LCBC Pt., PVD, HVOF 28 21 T1000 HPTB, TXWB HPTB, T900 HPTB

V01 Aluminise 14 11 T700 IPNGVV02 Aluminise, LVPS, APS 28 21 T900 IPNGV, T1000 IPNGVV03 LCBC Pt., LVPS, APS, PVD 28 21

• Witness simulation model for all coating processes used to model the art of the possible and the impact of capital investment, shift patterns, material standardisation and input patterns.

• SLA Reduction delivered in 2016. Shift Patterns changed to optimise flow. Other improvements planned in 2016 BPD.

• Lean training conducted with Production Leaders in SMED and VSM. This is supported by the use of video VSM to identify opportunities for lead time reduction.

• The most complex components have reduced from SLA’s of 28 days to 21 days.

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Future PlansExpanding BusinessTSTL Set to grow by 100% in the next 6 years. Large investment agreed over a 3 year period.

New TechnologyChanging the manufacturing process.

Demanding Customers!Lead time is a key strategic priority

Possible PlansUse of simulation as a decision making tool. Quantify the lead time benefit of capital investment. Detailed smaller scale models to optimise workflow.