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Innovatie in engineering bij FokkerEngineering & Supply Chain kunnen slimmer samenwerken – Workshop
Martijn van Rij 21 oktober 2015Manager Design EngineeringFokker Aerostructures BV
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Contents
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• Company overview• Innovation
– Product– Process
• Product development process– Past, Present, Future– Front loading strategy
• Front loading– High level architecture– Impact on way of working & organizational set-up
• Rudder-in-a-Month– Ambition / objectives– Challenges required elements– Developments
• Conclusions
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Fokker Aerostructures – Company overview
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• Fokker Aerostructures is a Tier 1 Aerostructures supplier for all the main aeronautical OEM’s
• Fokker will become part of GKNF35 in flight opening doors, flaperon
Dassault F5X empennage
Gulfstream G650 empennage
AW169 Thermoplastic horizontal
A350 outboard flap
Hondajet empennage
A380, GLARE® fuselage panelsThermoplastic leading edge
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Key Technology FML is applied A380 fuselage panels
GLAss REinforced aluminum A sandwich material constructed from alternating layers of aluminum and glass fiber with bond film.
• Weight reduction: 15 to 30%• Excellent Fatigue Resistance• Improved Impact Resistance• Excellent Fire Resistance Behavior
27 GLARE® fuselage panelstotal area ± 500 m2
Thermoplastic leading edge
InnovationFokker is well known through by its product innovation
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Key Technology Thermoplastics is applied on rudder and elevators (Gulfstream G650, Dassault F5X)
Induction welded, carbon, thermoplastic torsion box:• 20% cost reduction• 10% weight reduction
• JEC innovation award 2010
InnovationFokker is well known through by its product innovation
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InnovationOpportunities
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• OEM’s balance their innovation initiatives between incremental and disruptive innovation.
• Opportunities can only be realized when Non Recurring execution (hours & lead time) is competitive.
• This is especially true for incremental innovation:– Incremental innovation provides opportunities for early spin offs.– Incremental innovation can only be successful with low Non
Recurring Cost and short time-to-market.
• Besides product excellence, we need process excellence that addresses the market needs of today:
– Complexity management (incl. requirements & change management)– Organizational learning (transfer and re-use of domain knowledge)– Transformative innovation & growth (e.g. high volume aspects)
Innovatie in engineering bij Fokker
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Sequential product development process
Project setupRequirements
Design
Manufacturing
7
start
Tom
orro
ws
LTProject setup
requirements
design
manufacturing Initi
al L
eadt
ime
Knowledgelibraries
Front Loading
Toda
y’s
LT
Concurrent product development process
Front loaded product development process
1st ss delivery
Product development processPast, Present, Future
Innovatie in engineering bij Fokker
Project setup
Requirements
Design
Manufacturing
continuous integration of changes
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Product development processFront loading
• Front loading is a strategy to accelerate and improve the overall product development execution (reduce NRC hours & lead time) and performance (quality):
– Shift identification and solving of design problems to earlier phase of the product development process.
– Maturity of the design is achieved more quickly.– Knowledge is re-used and a standardized, predictable design
process is used by created and validated standard solutions.– Sensitivity and robustness of a standardized design is evaluated
upfront by design space exploration and driving design parameters.
– New concepts, knowledge and methodology generation and adaption of the software tool suite is done in the Front Loading phase. The Full Scale Development phase is executed with known, existing concepts, methods, tools and standards.
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DesignMaturity
Time100%
Improved overall maturityNovel design solutions
Traditional (labor driven)
Informationdriven
Product development processFast design maturity
Improved overall maturity, compliancy, change integration and controllability
Innovatie in engineering bij Fokker
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New Design - Build
Incrementaldesign
Product development processProduct recurring cost
• During the product development process, more and more decisions are being made, resulting in a higher maturity and decreasing influence on recurring cost.
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RC Cost fixed
Time
Informationdriven
100%
100%
Traditional (labor driven)
Informationdriven
80%
20%
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High level architecture of Front LoadingFocus on both complexity and lead time reduction
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complexity transfer /reduction
lead time gain due to simplicity
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2
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Impact on way of working & organizational set-upTechnical and social impact
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• New design process requires additional capabilities:– IT & software specialists (architectures, programmers)– Knowledge engineers– Engineers (design, stress, ME, specialists)
•
• Impact on career development:– A career will be a continuous learning experience.– Focus will be on deviations of the proposed design solution.– Working in a holistic design environment:
– Technical and business parameters are integrated– Multidisciplinary included in design review groups
– Knowledge development and innovation as core capability.
CURRENT STATE FUTURE STATERudder design lead time 18 months Rudder design in a month
Every solution is unique Standardized solutions
Design on the spot Frontloading; Prepare upfront
Use KBE only for know repetitive knowledge Use KBE to develop new knowledge
Expert creates results Experts evaluates results
Innovatie in engineering bij Fokker
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Rudder-in-a-MonthAmbition / objectives
• Operational excellence and lead time reduction in non-recurring phase by product and process standardization, in order to stay competitive:– Standardized design process. Workflow with integrated design logic and MDO.– Design process innovation.– Capture and re-use of knowledge. Formalizing tacit knowledge and best practices.– Real-time connection between knowledge and solution / geometry.– Automation of business process and tasks where possible and helpful.
• In order to:– Accelerate the execution of tasks on the critical path.– Reduce non-recurring cost of the total program by more than 50%.– React quicker to customer requests and changes.– Improve and expand available knowledge by front loading process and virtual rapid
prototyping, in order to aid and intensify the creative process.– Improve quality of the product and process by having a predictable design process,
performing more iterations and having automated requirements compliance checks.
• Show feasibility of integrated, complete, automated workflow.
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Technologies, tools & way of working Challenges required elements
• Elements required to apply the Fokker vision of the future development process:
– Workflow managers and Framework integrating processes and tools within a professional environment
– Mature KBE system– Mature MDO software and strategies– Simulation data management– Standards data management– Knowledge Management system– Design rationale tracking & traceability– Virtual laboratory– Bridge between structures engineering and software
engineering– Culture change of aircraft component engineers
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Rudder-in-a-Month developmentInitial scope (2014) – Hinge definitionCurrent scope (2015) – Torsion box
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RiaM 2014 – Project description
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RiaM 2014 – Use case 1Evaluate a hinge connection design
• Start with chosen standard solution with fixed parameter values and set of requirements based on current G650 hinge 3 design. Compute the behavioral properties of the design and evaluate whether the design complies to the requirements.
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RiaM 2014 – Use case 1Evaluate a hinge connection design
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Conclusions
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• Fokker vision to introduce front loading through design automation tools and techniques in the aircraft component development process is essential to remain competitive, but is also ambitious:
– Problem is often more complex than anticipated:– Many parameters, many interdependencies, specific knowledge required– Process definition, workflow and tools have large influence on flexibility– User interface to support concurrent engineering and maintain connection
to the product
– Level of modularity has big influence on the project:– High modularity: Flexible model, but highly complex interfaces– Lower modularity: Less flexibility, but interfaces better manageable– Speed can become a limiting aspect for optimization
• For realization of this vision partners such as software developers and knowledge institutes are required
• Biggest challenge will be for the engineers to work efficiently in the new development environment