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New supply chains, new manufacturing techniques

New aerospace education??

Jan VerbeekAmsterdam, 16 april 2010

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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 !!