Innovation and Training at Aerosud Dr. K. van Rijswijk Tuesday, August 11, 2009 SATN Annual Conference 2009 16-17 July Cap...
Outline <ul><li>Introduction Aerosud </li></ul><ul><li>Stability vs. Change </li></ul><ul><li>Aerosud Innovation & Trainin...
Introduction Aerosud <ul><ul><li>Formed in 1990 </li></ul></ul><ul><ul><li>Strong Engineering Design Capability  </li></ul...
Introduction Aerosud <ul><li>Aerosud Holdings: </li></ul><ul><ul><li>Aerosud Aerospace Systems:  </li></ul></ul><ul><ul><u...
Introduction Aerosud “ Innovate to prevent that contract is moved to a lower wage country” “ Innovate to maintain or incre...
Stability vs. Change <ul><li>Continuous quality is one of the most important aspects of aeronautical engineering: </li></u...
Stability vs. Change <ul><li>Innovation is an equally important aspect: </li></ul><ul><ul><li>New materials </li></ul></ul...
Stability vs. Change <ul><li>Production (Always the same) and Innovation (Continuous change) must not contaminate each oth...
Stability vs. Change Stability    Change Production    Innovation Proven technology   New technology Repeatability  ...
Aerosud ITC <ul><li>Aerosud Innovation & Training Centre: </li></ul><ul><li>Process Development </li></ul><ul><ul><li>Adva...
Aerosud ITC <ul><li>Development of new material applications and manufacturing technologies: </li></ul><ul><li>“ Saving ti...
Ingredients for Innovation <ul><li>Broad knowledge base </li></ul><ul><li>Customers (for who…?) </li></ul><ul><li>A networ...
Aerosud ITC Broad knowledge base Materials Processes Design
Aerosud ITC Broad knowledge base Materials Processes Design Testing Supplier relation Manufacturing equipment Tool design ...
Aerosud ITC Co-operation <ul><li>US: </li></ul><ul><li>Thermoplastic Composites </li></ul><ul><li>Titanium Machining </li>...
Funding <ul><li>Direct funding from customer </li></ul><ul><li>Own investment </li></ul><ul><li>Government funding: </li><...
Implementation Strategy <ul><li>Active marketing of companies to obtain contracts that involve the newly developed technol...
Example of Innovation <ul><li>Development of a composite sliding door for aircraft interiors: </li></ul><ul><li>Lightweigh...
Composite Sliding Door Innovation does not have to be “difficult”
Composite Sliding Door <ul><li>Material Selection: </li></ul><ul><li>Bending stiffness: Composite Sandwich panel </li></ul...
Composite Sliding Door Mechanical testing: “ confidence tests” Cyclic testing at UoT Static testing at ITC 75kg 75kg 185kg!
Composite Sliding Door <ul><li>Three routing concepts: </li></ul>Routing composite panel up to the skin Multi-step routing...
Composite Sliding Door <ul><li>Full scale cyclic testing at SABS </li></ul><ul><li>“ certification tests” </li></ul>
Composite Sliding Door <ul><li>INNOVATION? </li></ul>
<ul><li>UoT Student report: </li></ul><ul><li>Execution of work:  80% </li></ul><ul><li>Participation in innovation:  25% ...
Communication !!!!!!!!
<ul><li>Present: </li></ul><ul><li>UoT students excel at  implementing solutions ,…but are not  problem solvers .  </li></...
<ul><li>Future ambition: </li></ul><ul><li>In order to move up to the engineering level: </li></ul><ul><ul><li>Actively em...
Conclusion <ul><li>Innovation: </li></ul><ul><li>Is a skill </li></ul><ul><li>Right guy in charge, not necessarily an expe...
Questions? Dr. K. van Rijswijk Aerosud ITC 012-662 5336 [email_address]
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Innovation and Training at Aerosud by Dr K Van Rijswijk

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Dr K Van Rijswijk’s (Head of Advanced Composites, Aerosud Innovation and Training Centre, South Africa) presentation at the SATN Annual Conference 2009.

Theme: “Technological innovation at Universities in South Africa: towards industrial and socio-economic development”

16 - 17 July 2009
Cape Peninsula University of Technology
Bellville Campus.

Published in: Technology, Business
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Innovation and Training at Aerosud by Dr K Van Rijswijk

  1. 1. Innovation and Training at Aerosud Dr. K. van Rijswijk Tuesday, August 11, 2009 SATN Annual Conference 2009 16-17 July Cape Peninsula University of Technology Bellville Campus
  2. 2. Outline <ul><li>Introduction Aerosud </li></ul><ul><li>Stability vs. Change </li></ul><ul><li>Aerosud Innovation & Training Centre </li></ul><ul><li>Example of Innovation </li></ul><ul><li>UoT student characterization </li></ul><ul><li>Conclusions </li></ul><ul><li>Questions / discussion </li></ul>
  3. 3. Introduction Aerosud <ul><ul><li>Formed in 1990 </li></ul></ul><ul><ul><li>Strong Engineering Design Capability </li></ul></ul><ul><ul><li>Production => 750,000 Details/Assy’s per year </li></ul></ul><ul><ul><li>600 Staff </li></ul></ul><ul><ul><li>95% Export </li></ul></ul>
  4. 4. Introduction Aerosud <ul><li>Aerosud Holdings: </li></ul><ul><ul><li>Aerosud Aerospace Systems: </li></ul></ul><ul><ul><ul><li>Military Upgrades </li></ul></ul></ul><ul><ul><li>Aerosud Aviation: </li></ul></ul><ul><ul><ul><li>Design and Manufacture of Aircraft structures and interiors </li></ul></ul></ul><ul><ul><li>Aerosud Innovation and Training Centre: </li></ul></ul><ul><ul><ul><li>R&D, HCD </li></ul></ul></ul>
  5. 5. Introduction Aerosud “ Innovate to prevent that contract is moved to a lower wage country” “ Innovate to maintain or increase market share” “ Innovate to become a more attractive partner in challenging projects”
  6. 6. Stability vs. Change <ul><li>Continuous quality is one of the most important aspects of aeronautical engineering: </li></ul><ul><ul><li>Rules and regulations </li></ul></ul><ul><ul><li>Certified processes, materials and personnel </li></ul></ul><ul><ul><li>Records, paperwork and traceability </li></ul></ul><ul><ul><li>Testing and proof of compliance </li></ul></ul>Production requires a stable environment: “ Always the same” EASA Part 21 POA AS/EN9100
  7. 7. Stability vs. Change <ul><li>Innovation is an equally important aspect: </li></ul><ul><ul><li>New materials </li></ul></ul><ul><ul><li>New manufacturing processes </li></ul></ul><ul><ul><li>New designs and application </li></ul></ul><ul><ul><li>New management systems </li></ul></ul><ul><ul><li>New marketing methods </li></ul></ul><ul><ul><li>Knowing what the customer is going to want (trends) before he places an order: Can you guys make…Yes we can! </li></ul></ul><ul><ul><li>… </li></ul></ul>Innovation requires a dynamic environment: “ Continuous change”
  8. 8. Stability vs. Change <ul><li>Production (Always the same) and Innovation (Continuous change) must not contaminate each other: </li></ul><ul><ul><li>Spontaneous innovation might threaten stable production </li></ul></ul><ul><ul><li>Focusing on stable production might push innovation aside </li></ul></ul><ul><ul><li> Specialization!... With communication and an overlap </li></ul></ul>
  9. 9. Stability vs. Change Stability  Change Production  Innovation Proven technology  New technology Repeatability  Feasibility Communication
  10. 10. Aerosud ITC <ul><li>Aerosud Innovation & Training Centre: </li></ul><ul><li>Process Development </li></ul><ul><ul><li>Advanced Composite Technology </li></ul></ul><ul><ul><li>High-Speed Machining </li></ul></ul>
  11. 11. Aerosud ITC <ul><li>Development of new material applications and manufacturing technologies: </li></ul><ul><li>“ Saving time, costs and weight.” </li></ul><ul><li>Developing applications to maximize the benefit of the above mentioned technologies. </li></ul><ul><li>Training people at the same time to implement new technologies in the workshops. </li></ul>
  12. 12. Ingredients for Innovation <ul><li>Broad knowledge base </li></ul><ul><li>Customers (for who…?) </li></ul><ul><li>A network of experts (co-operation) </li></ul><ul><li>Funding </li></ul><ul><li>Infrastructure </li></ul><ul><li>Implementation strategy </li></ul><ul><li>Adventurous mind-set </li></ul>
  13. 13. Aerosud ITC Broad knowledge base Materials Processes Design
  14. 14. Aerosud ITC Broad knowledge base Materials Processes Design Testing Supplier relation Manufacturing equipment Tool design Assembly Finishes Design values Comparative studies Qualification Customer relation Design rules Processing envelope Parameters and variables Transport and Storage Legislation IP Costs
  15. 15. Aerosud ITC Co-operation <ul><li>US: </li></ul><ul><li>Thermoplastic Composites </li></ul><ul><li>Titanium Machining </li></ul><ul><li>CUT: </li></ul><ul><li>Direct manufacture </li></ul><ul><li>TUT: </li></ul><ul><li>Composites </li></ul><ul><li>High-speed machining </li></ul><ul><li>CSIR: </li></ul><ul><li>Composites </li></ul><ul><li>High-speed machining </li></ul><ul><li>Direct Manufacture </li></ul><ul><li>UJ: </li></ul><ul><li>Composites </li></ul><ul><li>AMT Composites </li></ul><ul><li>Material supplier </li></ul><ul><li>Epsilon engineering: </li></ul><ul><li>Tooling manufacturer </li></ul><ul><li>LST: </li></ul><ul><li>Composite manufacturer </li></ul><ul><li>ANDTc: </li></ul><ul><li>NDT </li></ul>
  16. 16. Funding <ul><li>Direct funding from customer </li></ul><ul><li>Own investment </li></ul><ul><li>Government funding: </li></ul><ul><ul><li>AMTS </li></ul></ul><ul><ul><li>Innovation Fund </li></ul></ul><ul><ul><li>Teta Training grants </li></ul></ul><ul><ul><li>EU funding </li></ul></ul><ul><ul><li>TIA </li></ul></ul><ul><ul><li>… </li></ul></ul>
  17. 17. Implementation Strategy <ul><li>Active marketing of companies to obtain contracts that involve the newly developed technologies </li></ul><ul><li>Training facilities </li></ul><ul><li>Funding </li></ul>
  18. 18. Example of Innovation <ul><li>Development of a composite sliding door for aircraft interiors: </li></ul><ul><li>Lightweight type of garage door (no Aluminium) </li></ul><ul><li>Fully flat/smooth surface when closed </li></ul><ul><li>FSTH compatible </li></ul><ul><li>Able to withstand a 90-kg abuse load without popping out of the rails </li></ul><ul><li>280.000 cycles (open-close) </li></ul>
  19. 19. Composite Sliding Door Innovation does not have to be “difficult”
  20. 20. Composite Sliding Door <ul><li>Material Selection: </li></ul><ul><li>Bending stiffness: Composite Sandwich panel </li></ul><ul><li>Fatigue resistance: Thermoplastic composite skin </li></ul><ul><li>Assembly: Bonding with epoxy adhesive </li></ul><ul><li>Front finish: Decorative laminate </li></ul><ul><li>Back finish: Flexible cloth </li></ul><ul><li>Side finish: Plastic capping </li></ul>
  21. 21. Composite Sliding Door Mechanical testing: “ confidence tests” Cyclic testing at UoT Static testing at ITC 75kg 75kg 185kg!
  22. 22. Composite Sliding Door <ul><li>Three routing concepts: </li></ul>Routing composite panel up to the skin Multi-step routing Bonding individual slats onto flexible skin 1 - Time-consuming 2 - Allignment difficult to obtain Selected method
  23. 23. Composite Sliding Door <ul><li>Full scale cyclic testing at SABS </li></ul><ul><li>“ certification tests” </li></ul>
  24. 24. Composite Sliding Door <ul><li>INNOVATION? </li></ul>
  25. 25. <ul><li>UoT Student report: </li></ul><ul><li>Execution of work: 80% </li></ul><ul><li>Participation in innovation: 25% </li></ul><ul><ul><li>No ideas, suggestion, thoughts, opinions </li></ul></ul><ul><ul><li>Not the proper communication skills to solve multi-disciplinary problems: </li></ul></ul><ul><ul><ul><li>How to express yourself in a discussion? </li></ul></ul></ul><ul><ul><ul><li>English (grammar, terminology, formulation) </li></ul></ul></ul><ul><ul><ul><li>Report writing, summarizing, presentations </li></ul></ul></ul>Composite Sliding Door
  26. 26. Communication !!!!!!!!
  27. 27. <ul><li>Present: </li></ul><ul><li>UoT students excel at implementing solutions ,…but are not problem solvers . </li></ul><ul><li>… This does not mean that UoTs are not innovation centres, I think you are doing a brilliant job! </li></ul>University of Technology Students Technician level Engineering level
  28. 28. <ul><li>Future ambition: </li></ul><ul><li>In order to move up to the engineering level: </li></ul><ul><ul><li>Actively embed “problem solving” and “innovation” in the curriculum </li></ul></ul><ul><ul><li>(knowing what football is does not make you automatically a football player) </li></ul></ul><ul><ul><li>Improve communication skills </li></ul></ul><ul><li>Trap: </li></ul><ul><li>If UoT students move up to the engineering level, who will become our technicians? </li></ul>University of Technology Students
  29. 29. Conclusion <ul><li>Innovation: </li></ul><ul><li>Is a skill </li></ul><ul><li>Right guy in charge, not necessarily an expert </li></ul><ul><li>Essential for the survival of an industry </li></ul><ul><li>Innovation and steady production must not contaminate each other, communication is essential </li></ul><ul><li>Network of experts is required, co-operation </li></ul><ul><li>UoT students can already successfully participate in an innovation process, but communication skills need to improve in order to become innovators / problem solvers. </li></ul><ul><li>Is successfully done at UoTs, don’t publish too much too early. </li></ul>
  30. 30. Questions? Dr. K. van Rijswijk Aerosud ITC 012-662 5336 [email_address]
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