honeywell aerospace mechanical oct 29, 2020 supply … · 2020. 10. 12. · honeywell aerospace is...

HONEYWELL AEROSPACE MECHANICAL

SUPPLY CHAINOct 29, 2020

© 2019 by Honeywell International Inc. All rights reserved.

1

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


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


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

3

Defense & Space | Customers


Contains Confidential Business Information Protected Under FOIA Exemption 4 and the Trade Secrets Act

D&S Products & Services Span ~ 300 Platforms

4

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


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


G03-999-64

36-150 Series

RE100

85 Series 131 Series

660

331 Series 700 SeriesRE200

6

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



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


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


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


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

© 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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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


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


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


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


16More competition for Superalloy Structural Castings

Ceramic crucible

Vacuum

Induction

Melter

Mold

Chamber

Investment MoldWax Pattern

Vacuum Casting – Structural


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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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


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


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

20

AM | The DFAM Process Flow


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


TEC9E991

(non-ITAR)

MATERIALIN718

22

AM Applications | RE220 HGT400 Surge Duct


23

AM Applications | M1A1 Tank Applications


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.

24

The Connected Strategy

Connected

Enterprises


COST WEIGHT QUALITY

25

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


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


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


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


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


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.

honeywell aerospace mechanical oct 29, 2020 supply … · 2020. 10. 12. · honeywell aerospace is...

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