dreams today technology tomorrow - value …€¦ · dreams today technology tomorrow csva annual...

DREAMS TODAY TECHNOLOGY TOMORROW

CSVA Annual Conference, Montréal

Keppel N Bharath

Senior Manager / Fellow PW800 Turbofan Program

2

DELIVERING MORE WITH LESS

-The future is linked with us bringing the nations together to solve the Risks that have been identified

-The Global Environment for business is more competitive and challenging than ever

-Our PEOPLE will transform our industries with game- changing products and technologies

-Let us embrace change and engage one another to drive the next generation of innovation

-Whatever you do must cost less to produce than today

3

UNITED TECHNOLOGIES

CORPORATION

Export Classification: No technical data

Commercial Engines

Military Engines

Aeropower

Aircraft Systems

Power, Controls &

Sensing Systems

4

A MAJOR CANADIAN EMPLOYER

Lethbridge

Mississauga

Halifax

Longueuil

Engine development and production

Corporate headquarters Engine development,

production and aftermarket

Engine production

Component manufacturing

Mirabel

Engine production Assembly & test

Flight testing

Ottawa

Manufacturing and R&D facilities

across Canada

Altitude test facility with the National

Research Council

Maintenance, Repair and Overhaul

Thompson

GLACIER

cold weather

testing and

research facility


5

Hawker Beechcraft T-6A JPATS

Embraer Super Tucano EMB-314

P&WC KEY BUSINESS SEGMENTS

Corporate

Military

Regional Civil helicopters

Aftermarket

General aviation

Dassault F7X

ATR 72 AgustaWestland AW139 Eurocopter EC135

Hawker Beechcraft King Air 350

Bombardier Q400

Embraer Phenom100

Maintenance, Repair and Overhaul

Customer First Centre

Cessna Sovereign


6

P&WC PRODUCT MANDATE

Auxiliary power units

PT6A

PW500

PW300

JT15D PW100

PW150

PW200

PT6T/B

PT6C

PW600

Turboprops 600 – 6,500 shp

PW800

Turboshafts 600 – 2,200 shp

Turbofans 900 – 20,000 lbf

PW900

Over 70,000 engines produced

10,000 Operators in 198 Countries


7

LEADING R&D INVESTOR

In Canadian aerospace

Over 1,400 engineering staff in Canada

$ CAD

Millions


423 466 472 481

457 454

378 385

473 527

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

8

70+ ENGINES CERTIFIED SINCE 1994

0

1994 1996 1998 2000 2002 2004 2006 2008 2010

Citation Excel PW545A

Bell 412

PT6T-3B

Eurocopter EC135

PW206B

Casa 295

PW127G

Bombardier Q400

PW150A

MD Explorer

PW207E

Dassault 2000EX

PW308C

HBC Hawker 4000

PW308A

Cessna XLS

PW545B

Dassault Falcon 7X

PW307A

Embraer Phenom 100

PW617F

Cessna Mustang

PW615F

10

20

30

40

50

60

70

HBC King Air 200GT

PT6A-52

Embraer Phenom 300

PW535E

Bell 429

PW207D

B747-8

PW901C


http://www.toymaxco.cc/extimages/p_HG8881.jpg

9

THE CONSTRAINTS ARE CHANGING

Globalization

Environment Costs

Workforce /

Manpower

Problem Statement: How do we do more with less with these constraints

Capacity


10

Copyright © Pratt&Whitney

Canada Cie.

VALUE METHODOLOGY OVERVIEW

ACE Operations Transformation - ‘03 3P, VSM, etc

ACE Launch - ‘98-’99

First Cells Achieve Silver Supply Chain Excellence - ‘00 ACE Tool Box, Master Methods,VSM

First Cell Achieves Gold - ‘02

KAIZEN - ‘93-’96

Q + ‘86-’90 Value Engineering - ‘96

Quality Function Deployment - ‘98

Risk Assessment - ‘01

Direct Value Measurement - ‘99

Product Function Specification - ‘98

Parametric Paired Comparison - ‘97

Parametric Cost Estimation - ‘00

Lean Engineering - ‘03 Project Mngt, EVM, etc.


11

CHALLENGE THE STATUS QUO

VISION STATEMENT :

Reduce the Build, Test & Pack time from 8 shifts to 8 hours MAURICE WEINBERG Exec offsite Sept 2002

Current lead-time T/Fan Proposed Lead Time PW600

Engine build 45 hrs 4.0 hrs

Engine dress 2.5 hrs 0.5hrs

Testing 6.5 hrs 2.0 hrs

Undress 2 hr 0.5hrs

Packaging 4 hr 1.0hrs

TOTAL 60.0 hrs 8.0hrs

GOAL:

1 Engine every 8 hours


12

THE PW600 VISION

Engine lead-time from 8 shifts to 8 hours


13

TECHNOLOGY FUNNEL

Needs structured methodology to deliver the identified value

Increasing TRL, reducing risk


http://www.custompartnet.com/wu/images/rapid-prototyping/dmls.png

14

Research &

Technology

Systems

Turbo

ECN

Dev’t Module

s -

Dis

cip

line &

Resourc

es M

anagem

ent

Engineering Services

Product Data and Business Processes

Business &

Finance

Human

Resources

Technical &

Quality

Support

Functions

New Product

Introduction

Support to

Operations

Product

Management

Product

of choice Research &

Technology

ENGINEERING STRUCTURE

Focused project management for technology development

15

TECHNOLOGY MANAGEMENT PROCESS

1. Product Technology

Strategy Definition

3. Technology Projects

Selection and Prioritization

4. Technology

Projects Management

5. Technology

Transfer to Programs

2. Idea Incubation

Process

TRL 1-5

TRL 6

TRL 0

Technology

Insertion (Programs)

TRL 6-9

1. Align Research activities with

Strategic priorities

2. Generate and incubate innovative

ideas

3. Optimize R&D Investment by

proper project selection &

prioritization

4. Minimize time and cost from idea

generation to entry to service

5. Introduce mature technologies to

engine program to minimize

development risks and maximize

competitive advantage

6. Leverage global funding and talent

16

Concept initiation Concept optimization Preliminary design Detail design

1

2

3

4

5

6

TRL

IPD Phase:

Passport: 0 1 2

Technology Readiness Level Progression


1

2

3

4

5

6

TRL

IPD Phase:

Passport: 0 1 2



1

2

3

4

5

6

TRL

IPD Phase:

Passport: 0 1 2


Technology

Development

Plans

)

Technology

Development

Plans

)

Product

Opportunities

Product

Opportunities

Required

Validation

Required

Validation

Technology

Development

Planning

Technology

Development

Planning

Technology Plan

Technology

Development

Planning

Technology

Development

Planning

Technology Plan

Technology

Portfolio

Technology

Portfolio

9

8

7

6

5

4

3

2

1

TRL

Levels

In service

Qualification/

certification

Flight test

System-level

validation

Rig/core

(expanded design

space)

Rig test (minimaldesign space)Rig test (minimaldesign space)

Proof-of-concept

Technology

application

Basic principles

System

Technology

Requirements

System

Technology

Requirements

Technology 1

Technology 2

Technology 3

Technology 4

..............

Technology

Prioritization

Technology

Prioritization

Technology 1

Technology 2

Technology 3

Technology 4

..............

Technology

Prioritization

Technology

Prioritization

Customer & Market

Requirements

Customer & Market

Requirements

Product & Service Plan

Thru

st

Year

Customer & Market

Requirements

Customer & Market

Requirements

Product & Service Plan

Thru

st

Year

Advanced Design

Studies

Advanced Design

StudiesAdvanced Design

Studies

Advanced Design

Studies

Validated

Technologies

Validated

Technologies

Technology

Insertion

Technology

InsertionTechnology

Insertion

Technology

Insertion

Technology

Validation

Technology

ValidationTechnology

Validation

Technology

Validation

INNOVATION IS KEY….MADE ON EARTH Develop technologies worldwide in Parallel Globalization


17


Canada Cie.

INPUTS • Risk Assessment

• Risk Exposure

• Risk Cube

• Past Risk Mitigation Experience

• Alternative Plan Possibilities

OUTPUTS • Risk Mitigation Plan

• Waterfall Chart

• Risk Reduction Monitoring

(%)

RISK ASSESSMENT IN MITIGATION OUT


18

WHEN & WITH WHOM TO INVEST

Low High

Degree of Competitive Advantage

Develop

Partner

Procure

Commercial available

to all competitors but

required to maintain

competitive parity

Commercially

available but unique

application creates

competitive advantage

Technology creating

unique competitive

advantage


19

WHERE TO INVEST

For technology development, the value equation requires an

additional term

Success probability is required due to the high degree of

uncertainty around innovation

Value = Potential Benefit x Probability of Success

Non Recurring Engineering Investment


20

ENVIRONMENTAL FOOTPRINT Develop a Total Environmental Footprint Model

CO, VOC, NOx, smoke, ICAO

Regulations, Landing fee

surcharges, health effects

Optimize Manufacture logistics based on Greenhouse gases

And KW/ KG of energy required

ATR 72

Environment


21


Canada Cie.

The long Road to PW600 Value

Event No

Pro

du

ct

Event DescriptionEvent

Type

VE-1999-147 GA Engine Market Analysis DVM

VE-1999-142 GA Engine RGB FA

VE-2003-347 PW610 Manufacturing Review QFD

VE-2003-329 PW610 Production Plan QFD

VE-2003-343 PW615 Key characteristics definition QFD

VE-2002-288 GA Market Values for GA QFD

VE-2001-261 PW610 PW610 QFD Session QFD

VE-2000-220 PW6xx New concept QFD

VE-2002-305 PW610 Risk Assessment - Program Risk

VE-2002-313 PW610 Risk Assessment Risk

VE-2003-363 PW610 Risk on Thermal Mgmt Risk

VE-2002-314 PW615 Risk Assessment Risk

VE-2002-304 PW6xx Combustor / fuel manifold Risk

VE-2002-279 PW6xx Riak Assessment Review / Update Risk

VE-2002-292 PW6xx Low Cost EEC: Risk Assessment Risk

VE-1999-152 GA Gas Turbine Blade TRIZ

VE-1999-164 GA LP Shaft TRIZ

VE-2000-179 GA Total Engine VE

VE-2000-196 GA TP Assy & Test Process VE

VE-2001-243 PW610 Function/Cost analysis VE

VE-2002-325 PW615 Monocase VE

VE-2003-366 PW615 VE with suppliers TOP 32 parts VE

VE-2001-254 PW6xx Bearing Housing-Cost red KFW VE

VE-2001-260 PW6xx PW625 TEC VE session VE

VE-2002-281 PW6xx VE Cost reduction - AGB Oil Tank VE

VE-2000-222 PW6xx Cost and weight/ LPC, HPC VE

VE-2000-213 PW6xx Cost / Producibility VE

• 50 % Parts count reduction

• 5 Rotating stages Vs. 8

• 3-5% better performance

• 10% better thrust to weight

• Adapted for volume production

• Easier maintenance

• Competitive durability

• Proven technology

• Uncompromised reliability

22 PWC Proprietary Data

CGP CONTROLLED

NOVEL MANUFACTURING TECHNOLOGY

Status

Moving line is activated when 100% of components released to floor.

Build time for an engine video taped at 3:58

Incremental improvements required to go to 3:30

Next steps

Copy line to all production facilities

Overhaul Challenge

Reverse line flow at the overhaul shop to achieve a 7 day Turn Around Time for field

engines

GOAL: 1 ENGINE EVERY 8 HOURS

Assembly Moving Line 1 month inventory 27 Producers for full Engine Forward Stocking Location

23

Copyright ©

Pratt&Whitney Canada

Cie.

Conclusions

Whenever great minds get together to solve issues great things happen

The World is Flat. Use that fact to our advantage

If given the opportunity , YOUR PEOPLE can transform the Industry with

game changing Technologies and Products

Let us embrace change and engage one another to drive the next

generation of innovation

PWC Proprietary Data

CGP CONTROLLED

dreams today technology tomorrow - value …€¦ · dreams today technology tomorrow csva annual...

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