honeywell aerospace mechanical oct 29, 2020 supply … · 2020. 10. 12. · honeywell aerospace is...
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HONEYWELL AEROSPACE MECHANICAL
SUPPLY CHAINOct 29, 2020
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© 2019 by Honeywell International Inc. All rights reserved.
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Agenda
• Aerospace Product Line – Engines & APU’s
• Current Aerospace Market Situation & COVID-
19 Impacts
• Manufacturing Process Selection
- IC vs. AM vs Forging vs Machining
• Investment Casting Supply Chain
• Additive Manufacturing
• Honeywell Connected Strategy
• Summary
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© 2019 by Honeywell International Inc. All rights reserved.
Profile | Honeywell Corporate 2
AerospaceHome and Building
Technologies
Performance Materials
and Technologies
Safety and Productivity
Solutions
Our products, software, and technologies are in more than 150
million homes and 10 million buildings worldwide, helping
customers control their comfort, security, and energy use.
We develop advanced materials, process technologies, automation solutions, and industrial software that are revolutionizing industries
around the world.
We improve enterprise performance and worker safety and productivity with our scanning and
mobile computers, software, warehouse automation solutions,
and personal protective equipment.
Our products are used on virtually every commercial and defense
aircraft platform and in more than 100 million vehicles worldwide and include aircraft propulsion, cockpit systems,
and satellite communications.
$14.8B Sales
$9.8B Sales
$10.3B Sales
$5.6B Sales
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© 2019 by Honeywell International Inc. All rights reserved.
Contains Confidential Business Information Protected Under FOIA Exemption 4 and the Trade Secrets Act
• U.S. Air Force
• U.S. Army
• U.S. Navy / Marines
• International MoDs
• Boeing
• Raytheon
• Lockheed Martin
• Northrop Grumman
• SAAB
• UK Ministry of Defense
• Hindustan Aero Ltd. HAL
• Japan Ministry of Defense
• BAE Systems
• Dassault
• EADS
• Finmeccanica
• Boeing
• Lockheed
Martin
• Thales
• Orbital
Our Key Customers Advance Technology To Serve & Protect
OEMs / Aftermarket
International
Space Missiles & Munitions
• Boeing
• Lockheed
Martin
• Aselsan
• Rafael
• Raytheon
• ATK
• MBDA
• BAE
Systems
Ground, Sea, Air and Space Experience
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Defense & Space | Customers
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© 2019 by Honeywell International Inc. All rights reserved.
Contains Confidential Business Information Protected Under FOIA Exemption 4 and the Trade Secrets Act
D&S Products & Services Span ~ 300 Platforms
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DoD, Civil, andCommercial Space 30+ platforms
Human Space10+ platforms
International20+ platforms
Army, Navyand Air Force60+ platforms
BomberAircraft3 platforms
Fighter/Attack/ Trainer Aircraft30+ platforms
Special Mission/ UAV Aircraft20+ platforms
Mobility/TankerAircraft40+ platforms
Military Helicopters20+ platforms
Surface/ SoldierVehicles
15+ platforms
Commercial Helicopters20+ platforms
Naval Platforms10+ platforms
Defense & Space | Products & Services
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© 2019 by Honeywell International Inc. All rights reserved.
5
Propulsion Systems Product Lines
OVER 72,000 TURBINE ENGINES DELIVERED SINCE 1959
TURBOFANENGINES
3,000 to 10,000 lb. Thrust
for Commercial and
Military Aircraft
TURBOPROPENGINES
575 to 1,600 SHP for
Commercial and
military aircraft
TURBOSHAFTENGINES
500 to 5,000 SHP for
Tanks, Commercial
and Military Rotorcraft
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© 2019 by Honeywell International Inc. All rights reserved.
G03-999-64
36-150 Series
RE100
85 Series 131 Series
660
331 Series 700 SeriesRE200
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APUs –
Large Installed Base & Poised for Growth
AIR TRANSPORT & REGIONAL
~18,000 In service
BUSINESS AVIATION
DEFENSE & SPACE
>95,000 APUs Shipped
>36,000 in Service
~9,000 In service
~9,000 In service
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© 2019 by Honeywell International Inc. All rights reserved.
© 2019 by Honeywell International Inc. All rights reserved.
Broad Defense Propulsion Applications
Defense Propulsion
T800/1/2
CTS800
Platforms: 2
A/C in Service: 35
AGT1500
LV50
Platforms: 1
T/s in Service: 7500
F124
F125
Platforms: 4
A/C in Service: 280
T53
LT101
HTS900
Platforms: 9
A/C in Service: 5500
Predator B
Reaper
Platforms: 1
A/C in Service: 500
MA
RK
ET
SP
RO
DU
CT
S AL5512
T55
T55-715
Platforms: 4
A/C in Service: 1200
AttackHelicopter
LandCombat
Systems
Fixed WingFighters/Trainers
Light Utility
Helicopter
Fixed WingUAV/UCAV
Heavy Lift
Helicopter
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© 2019 by Honeywell International Inc. All rights reserved.
8
Honeywell Aerospace| Current Market Conditions
• Aerospace business is down due to COVID-19 - travel drop off anywhere
from 0 to 70% - Heavily dependent upon the market segment
- Business jets are nearly back to baseline
- Military may be up
- Commercial down up to 70%
• Airlines are scavenging parts from their idled fleet
• Airlines are scrapping older jets and not allowing them to be purchased by
low cost carriers
• Airlines have severely downsized the purchasing of new aircraft
• Due to reduced business travel, virtual events, restrictions on travel abroad
commercial travel is expected to be at most 80% of 2019 by end of 2021
• Honeywell and others have significantly right sized their workforce
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© 2019 by Honeywell International Inc. All rights reserved.
9
Supply Chain – PO Placement Considerations
Investment
Caster Tier 1
Supply Chain Levels
Tool Shop Tier 2
Metal
ProducerTier 3
Manufacturing Readiness
Levels (MRL)
Honeywell
Systems
Supplier
Quality
Systems
Special
Processes
APSL, Fixed
Process, Product
Requirements ...
Quality Assurance
The supplier’s MRL, QA, Tier Level etc. affect the PO Placement
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© 2019 by Honeywell International Inc. All rights reserved.
10• Hog-Out of Plate or Bar Stock – reduces risk, schedule and cost
- Simple Part shape, Low Quantities - +/- .030 on non-machined surfaces
• Investment Casting
- Moderate complexity, moderate quantities - >100 parts total, moderate mechanical properties and casting
alloys (MarM-247 etc.)
• Sheet Metal Fabrication
- Thin walls
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© 2019 by Honeywell International Inc. All rights reserved.Honeywell Proprietary. Use or disclosure of information on this page is subject to the restrictions on the title page.
Investment Casting offers strong combination of shape/dimensional/mechanical
capabilities – Challenged by long lead times and upfront NRE/Tooling
Metal Manufacturing Processes Compared
= best
Powder Bed
(laser)Investment Cast Forging Machining
Wall Thickness
+++ ++ ++ ++++
Build Speed
++++ + + +++
Roughness
+ ++++++++
Mechanical Properties++++ +++ + ++Shape Complexity
+++++++ +++
Repair Capability
+ + +++ ++++
Multi Material Capability
+ ++ +++ ++++
Size of the Part ++ ++ ++++ ++++
Hollow, Lattice, Topology
Lead Time
++++ ++
Accuracy
+++ + ++ ++++
NRE/Tooling Cost per Unit – Quantity
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© 2019 by Honeywell International Inc. All rights reserved.
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Sand Cast Investment Cast
Permanent Mold
Low Pressure
Casting selection is based on part quality, quantity and cost requirements
Sand Casting lower cost than IC
Investment Casting much fewer
suppliers
Perm. Mold for valve bodies
and other common componentsLow Pressure mostly for wheels
Casting Process Selection
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© 2019 by Honeywell International Inc. All rights reserved.
13Vacuum IC is the most constrained supply chain with few real high quality producers
Investment Cast Unit
• Whitehall
• Dover
• Wichita Falls
Avoiding Microstructure
NC’s can be challenging
SC Supply Chain
capabilities are
concentrated
SC Casting Processes are
Unique vs. Other IC parts
Vacuum Casting - Airfoils
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© 2019 by Honeywell International Inc. All rights reserved.
14Integral wheels may be the most challenged supply chain in terms of #
producers and product difficulty
Investment Cast Unit
• LA Porte
Crucibles
IC Molds
Vacuum Casting – Rings & Stators
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© 2019 by Honeywell International Inc. All rights reserved.
15Only a few titanium aerospace casters in the US qualified by Honeywell
Induction Skull
Remelting
Vacuum Arc
Remelting
Copper crucible
Chemical Milling
Weld RepairHot Isostatic Pressing
Titanium Structural Casting
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© 2019 by Honeywell International Inc. All rights reserved.
16More competition for Superalloy Structural Castings
Ceramic crucible
Vacuum
Induction
Melter
Mold
Chamber
Investment MoldWax Pattern
Vacuum Casting – Structural
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© 2019 by Honeywell International Inc. All rights reserved.
17
Cost and time to produce wax tooling is one of the
biggest hurdles to new OEM product introduction
Product Engineer creates the tooling drawing
Process Engineer designs gating
Wax Injection Press
Injection Tooling
Wax Assembly
Machining injection molds is a critical element to
setting the pace of new engine development
Tooling & Wax Assemblies
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© 2019 by Honeywell International Inc. All rights reserved.
18
Additive Manufacturing | Honeywell’s Long Experience
INITIAL DEVELOPMENT
of prototype parts with external vendors
DMLS 718 swirler on Airbus
FLIGHT TEST BED
DMLS 718 Tangential
On Board Injector on FLIGHTTEST BED
FULL SCALE PRODUCTION
REACTIVE METALS lab opens
PRODUCTION FACILITY opens
OPENING OF FIRST AM LAB in Phoenix
and subsequent Global sites
1ST FAA CERTIFIED
PARTDELIVERED
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019
Material B-Basis Established
- Ni, Al, SS, Ti
SUPPLIER APPROVALS
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© 2019 by Honeywell International Inc. All rights reserved.
B L D G . 1 1 4
REACTIVE
METALS LAB
Primarily Al and Ti alloys
Laser and EBM
powder bed machines
Powder handling and
recycling equipment
B L D G . 3 0 1
R&D LAB
Material and process development
Prototype and tooling fabrication
AM Prototypes and Tooling
B L D G . 1 0 2
PRODUCTION FACILITY
Primarily Nickel and
Stainless Steel Alloys
Laser powder bed machines
Powder handling and
recycling equipment
In-house post-processing
– HT, HIP, and machining
Commitment to AM | Phoenix AM Manufacturing Centers
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© 2019 by Honeywell International Inc. All rights reserved.
REQUIREMENTS DESIGN OPTIMIZATION
BUILD PREPARATION
MANUFACTURING
Voice of customer
Existing parts /
drawings
New Technology
Technology Roadmap
Load cases
Temperature
Assembly
3D Scans
Process/Material
Selection
Process Contraints
Material Models
Process &
Material Selection
Process Constraints
Topology Optimization
Lattice Materials
Equipment Selection
Material Selection
Repair
Orientation
Slicing
Support
Toolpaths
Processing
Post-processing
Inspection
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AM | The DFAM Process Flow
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© 2019 by Honeywell International Inc. All rights reserved.
COMBUSTORS
STATORS
HOUSINGS
TOBIS
DUCTING
AIRFOILS
APU OIL
BAFFLE
ENGINE MOUNTS
BUFFER AIR
TUBES
EVERY SECTION
OF ENGINE
HAS AM
OPPORTUNITIES
HONEYWELL
TARGET ENGINE
APPLICATIONS
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© 2019 by Honeywell International Inc. All rights reserved.
TEC9E991
(non-ITAR)
MATERIALIN718
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AM Applications | RE220 HGT400 Surge Duct
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© 2019 by Honeywell International Inc. All rights reserved.
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AM Applications | M1A1 Tank Applications
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© 2019 by Honeywell International Inc. All rights reserved.
C O N N E C T E D
AIRCRAFT
130K TOTAL
AIRCRAFT
C O N N E C T E D
BUILDINGS
10M GLOBAL
INSTALLED BASE
C O N N E C T E D
HOMES
150M GLOBAL
INSTALLED BASE
C O N N E C T E D
PLANTS
10K+ GLOBAL
INSTALLED BASE
C O N N E C T E D
WORKERS
550M GLOBAL
PPE USERS
C O N N E C T E D
SUPPLY CHAIN
LARGE GLOBAL
INSTALLED BASE
A connected world is made up of connected cities and industries, run by connected companies.
MANY ARE TALKING ABOUT IT, HONEYWELL IS DOING IT.
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The Connected Strategy
Connected
Enterprises
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© 2019 by Honeywell International Inc. All rights reserved.
COST WEIGHT QUALITY
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Connected Manufacturing| Honeywell’s Digital Enterprise
Honeywell Aerospace is leveraging our Industrial Software leadership in supplying IIOT and Digital
Enterprises to a wide array of industries and products.
Advanced Technology is working to integrate these digital capabilities into Aerospace products,
factories and supply chains. Examples include:
• Advancing data analytics/machine learning to rapidly analyze production data and speed up
new part process development
• Developing new sensors and analytics to expand the portfolio of data collected during
turbine engine operation
• Advancing multi-material and high temperature material manufacturing processes to enable
improved SFC and longevity in turbine engines
• Connecting our supply chain to better inform engine and Aerospace platform operators to
part performance, life and supply challenges
Aerospace systems need rapid access to digital enterprises to ensure
optimal performance, efficient maintenance and responsive R/O
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© 2019 by Honeywell International Inc. All rights reserved.
Digital Twin and Data Analytics/ML Integration
LANDING GEAR SYSTEMS
Wing Landing
Gear RH
Nose Landing
Gear
Wing Landing
Gear LH
ENGINES AND APU’S
HONEYWELL-AERO IS A LEADER IN APPLYING DIGITAL SOLUTIONS INCLUDING FIELDING DIGITAL TWINS
Real-Time Decision SupportPredictive Analytics And Fleet
Management Support
Maintenance & Ops Decision
Support
Engineering Analysis and
Support
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© 2019 by Honeywell International Inc. All rights reserved.
SMART BUILDINGS
• Energy Management Dashboard
• Smart HVAC
• Resource Allocation via Geofencing
DATA ANALYTICS
• Data Analytics/ML identify Actionable Insights
• Next Build Recommendations
• QA Metrics including Alerts
PROCESS & CONTROL
• SMART QA Dashboard
• Real-Time SPC Access
• Active Work Order Tracking
CONNECTED WORKERS
• Equipment Status Alerts
• Real time WI - Maintenance Record Access
• Safety Exposure Monitoring
SENSORS
• In Chamber KPIV Sensors
• Process Out of Tolerance Alerts
• Equipment Performance Trend Analysis
• Factory Level Secure Connectivity
SECURITY
• Build File Blockchain Encryption
• File Revision Validation
• Single Use File Protection
Connected Manufacturing| Honeywell Creating Smart Connected Ecosystem
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© 2019 by Honeywell International Inc. All rights reserved.
DATA
COLLECTING
SENSORS
Leveraging Data Analytics/ML/AI to Create a Smart Connected Ecosystem
INABILITY TO
PROCESS DATA
HONEYWELL
ANALYTICS
Within the AM process
there are huge numbers of
sensors collecting data
AM Manufacturers are working to leverage value
of in-process data but much work still to be done
Honeywell is applying Data
Analytics to AM which will
enable cost savings, better
manufacturing and safer
parts.
Data Analytics | Advancing AM Build Process
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© 2019 by Honeywell International Inc. All rights reserved.
THE
SECURED
CLOUD
INDUSTRY FACTORY WORKER DEPOT FORWARD
OPERATING BASE
Parts
Management
Training
Design
Build Files
Logistics
Connected Manufacturing | AM’s Role in the Supply Chain
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© 2019 by Honeywell International Inc. All rights reserved.
Implementation| Overcoming Value Proposition Hurdle
Manufacturing Leaders must be very cost focused – Smart Manufacturing
innovations must buy their way onto the factory floor
• SM implementation efforts should target specific manufacturing issues with clear cost savings –
yield improvement, labor or material use reduction
• SM service providers should understand enough detail about the implementation location (factory
operations) that they can help craft the value proposition and implementation strategy – especially
with small to medium sized manufacturers
• SM implementation opportunities should not be too broad in scope or long in implementation
duration - Production line(s) in single location with less than six months is ideal
• SM implementation should use the simplest technologies (sensors/data analytics etc.) that will get
the job done
• The target factory needs a champion of IIOT
• The SM integrator needs to make sure the “Actionable Insights” are actually acted upon – applying
data analytics to new sensor data does not add value if engineers/operators don’t improve their
decision making.
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© 2019 by Honeywell International Inc. All rights reserved.
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