A new approach to Weight ManagementLuisa Rovera ICT - Simulation Data Management, CAE & CFD2013 Altair Technology ConferenceTurin, April 24th 2013
ABSTRACTA proper Weight & Balance management is a must for AgustaWestland, as it can identify areas where it is possible to save emptyweight to improve helicopter pay load capacity and it can trace potential weight increments that might lead to customers’ claims.In terms of technology, two main applications were delivered to foster AW Weight & Balance management process: Weight Assistant: to extract advanced weight information from CAD environment. Weight Analytics: to empower the Engineers and Executives to make better and faster decisions by managing the entire Weight &Balance processWeight Assistant, an integrated CATIA V5 application to promote AW methodologies standardization; this application performs arealistic weight prediction and guarantees repeatability over time and user independence, thanks to an unambiguous classification ofweight calculation rules per components and Departments.Furthermore, the automatic calculation of main aircraft consumables (sealant, paint ...) contribution has been implemented.Weight Analytics, openly architected and highly configurable tool, allows to visualize, analyse and predict W&B at any point in timeduring the entire Product Life Cycle, and streamline time consuming repetitive tasks associated with data consolidation.This application reduces the time requested to asses Weight & Balance and it improves both quality and robustness with integrated,transparent and standardized automation to consolidate data sources combined with best-in-class methods in Business Analytics.The approach of Weight Analytics supplies a common and integrated environment for the management and monitoring of the productweight since the very first phases of the product concept development: indeed Weight Analytics architecture is grounded on afunctional view approach, a way to manage, coordinate and consolidate inputs to the design process coming from a number ofstakeholders, both internal or suppliers.
Weight Analytics and the Product Life Cycle“AgustaWestland Weight Analytics” (AWWA) supports W&B engineering all over the phases of product lifecycle by managing and tracing BOMs and calculation with different product views:• during Concept & Feasibility, W&B is supporting the General Design & Architecture functions withfunctional W&B studies at product level and system level, W&B data are modified without any changecontrol;• during Design & Development W&B engineering is managing both, the functional and the physicalproduct structure, with change control;• during Serial Program phase, W&B engineering is tracing the physical product structure, with changecontrol.
Main Phases of the Weight & Balance Process• The management of mass data will be based on "Target Setting" and "Target Monitor" logic, throughout allstages of development.• Typically a new project starts identifying a product as a reference• From this reference we start to identify the content of the new product, according to its requirements by themanagement of the "carry-over" parts and new specific parts.Reference BaselineBaseline UpdateMass TargetsCurrent Design of the New PrdStrutturaSistemiPotenzaComfortSicurezzaFinizioni0 20 40 60 80 10084.318.517.58.723.663.627.4 27.438.634.646.945Review1 Review2Baseline Target Current253237BL PR1 PR2ECR/ECOECR/ECOECR/ECOSis 1Sis 2Sis 3Sis 4Sis 5W&BReferenceTargetCalculatedEstimatedWeighed
Main Phases of the Weight & Balance ProcessWeight evolution management:prediction, calculation, reconciliation, weighting: Continuous weight verification, amendment and alertconsidering:– accurate target weight definition– designed parts calculated weight verification– calculated weight vs. target weight comparison– actual weight vs. calculated weight reconciliation– actual weight conformityWeight Management in the lifecycle andcontractual requirements compliance, providing: H/C Weight prediction Helicopter weight aggregation(Breakdown per P/N, per military codes, material )Within the engineering process of a new product, the current statusof development is measured both against the baseline weight andthe target weight. The baseline weight changes along thedevelopment every time a change occurs.The engineering process of new parts articulates along severalrevisions, trials and errors, which involve each single component ofthe EBOM. AWWA keeps always track of such a changingframework and returns the weight manager the exact currentposition of the engineering process, detailed along all the EBOMitems.For each item the weight manager can recognize the currentweight, the level of accuracy of the data CoG, inertias and thehistory of revisions. That way he can always perform a detailed andreliable review and analysis to plan how to move forward.
Weight Assistant:Calculation Engine into Catia V5Based on the classification of the currently adopted weight calculation rules perrelevant Components of each Department, Weight Assistant isan integrated CATIA V5 application developed to:DEPARTMENT:AIRFRAMESYSTEMCOMPONENTCALCULATIONCATEGORYAngular,bracketMETALLICFirewallGridCowling skin CompositeSealMANUALINPUTOther (to bespec.)Promote AgustaWestland designmethodologiesstandardizationGuarantee repeatability over timeand user independence
To predict the most accurate and realistic weightduring the product development phase, an easyway to extract the contribution of mainconsumables has been implemented.Weight Assistant:Calculation Engine into Catia V5
Weight Analytics and Functional Views• The “view” is a representation of the product composition, where all the components are managed and groupedinto different hierarchical levels accordingly to aggregation rules.• Each product can be represented according different logics and rules, corresponding to different typology ofstructures.• The functional structure is a unifying element between the different views of all the experts involved in thedevelopment process, and frequently corresponds to the vision of the top management.Engineering ViewTypical View ofdesigners andtechnicians, definedaccordinglyfunctionalsubsystems, tied toCAD tools andreported in the PLMManufacturing ViewVery flat View of theproduct, directlylinked with theworkflow across themanufacturing linesand tooling units inthe plants.OI6r241990OI7r--OI1r24OI5r24OI3r24OI4r5OI2r10OI8r--Dis 1 Dis 3Dis 6Dis 4Dis 5Dis 2Dis 7 Dis 81212AWWAFunctionalViewsFunctionalViewsEngineeringManufacturing
SAWE Functional View example• The Society of Allied Weight Engineers is an international organization whose purpose is to promote the recognition ofWeight Engineering as a specialized branch of engineering. The Society is organized into 22 chapters with membersfrom across the United States, Europe, United Kingdom, and Canada.• The Society offers to members and industry a medium for the pooling and exchange of data and experience at localand regional levels, fostering a higher degree of efficiency in mass properties engineering topics.
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W&B Process and Analytics• Quick, reliable and currentupdate of product weight status.• Powerful BA tools to analyze andcompare BOM composition andattributes, to support decisionson how to move forward andminimize risk.• Based on the functional-viewapproach, it offers a way tomanage, coordinate andconsolidate inputs to the designprocess coming from a numberof stakeholders, both internal orsuppliers.• The Weight Analytics solution provides high data consistency and transparency, standardization andautomation of workflows, enhanced tools to support analysis and decision-making, leveraging best-in-classmethods from the Business Analytics world.
Advantages from the AWWA System• Empowerment of qualified workforce– AWWA relieves engineers from data retrieval recurrent tasks and bring them back to dataanalysis and design intensive activities, which return a significantly higher added value toprocess and product quality.• User’s rights management– AWWA allows to identify and track process and data owners, in order to easily clearifyresponsibilities and fairly deal with possible conflicts.• User’s role management– AWWA solution offer different views and accesses for different users, to be modeledaccording the company extended (e.g. including suppliers) organization structure. This isespecially crucial where strict confidentiality rules apply by authorities’ or customers’request.• Enhanced prediction capacity and risk management– AWWA offers managers the possibility to foresee the impact of changes occurring in thefuture, to perform what if analysis, and eventually cut the risk factors.
Advantages from the AWWA System• Consistency and stability of information– AWWA technology provides high data consistency and transparency, standardization andautomation of workflows, across distributed data repositories and process owners.• Standard and regular reporting– AWWA enables a protocol of standard and regular reporting - targeted to differentrecipients across the company’s organization infrastructure.• Advanced analytics– AWWA provides sophisticated calculations, analysis and KPIs that are performed quicklyautomatically by the system.• Interface between PLM, ERP and early design phases– AWWA provides concept engineers and architects an effective toolkit to quickly andreliably manage early design phases and streamline the evaluation/feasibility studies thatend to the detailed design stage.