Engineering meets supply chain > Fokker

1. Innovatie in engineering
bij Fokker
Engineering & Supply Chain kunnen slimmer
samenwerken – Workshop
Martijn van Rij 21 oktober 2015
Manager Design Engineering
Fokker Aerostructures BV

2. FOKKER UNCLASSIFIED
Contents
Innovatie in engineering bij Fokker2
• 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

3. FOKKER UNCLASSIFIED
Fokker Aerostructures – Company overview
Innovatie in engineering bij Fokker3
• Fokker Aerostructures is a Tier 1 Aerostructures
supplier for all the main aeronautical OEM’s
• Fokker will become part of GKN
F35 in flight opening doors, flaperon
Dassault F5X empennage
Gulfstream G650 empennage
AW169 Thermoplastic horizontal
A350 outboard flap
Hondajet empennage
A380, GLARE® fuselage panels
Thermoplastic leading edge

4. FOKKER UNCLASSIFIED
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 panels
total area ± 500 m2
Thermoplastic
leading edge
Innovation
Fokker is well known through by its product innovation
4 Innovatie in engineering bij Fokker

5. FOKKER UNCLASSIFIED5 Innovatie in engineering bij Fokker
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
Innovation
Fokker is well known through by its product innovation

6. FOKKER UNCLASSIFIED
Innovation
Opportunities
6
• 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

7. FOKKER UNCLASSIFIED
Sequential product development process
Project setup
Requirements
Design
Manufacturing
7
start
TomorrowsLT
Project
setup
requirements
design
manufacturing
InitialLeadtime
Knowledge
libraries
Front
Loading
Today’sLT
Concurrent product development process
Front loaded product development process
1st ss delivery
Product development process
Past, Present, Future
Innovatie in engineering bij Fokker
Project setup
Requirements
Design
Manufacturing
continuous integration of changes

8. FOKKER UNCLASSIFIED
Product development process
Front 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.
Innovatie in engineering bij Fokker8

9. FOKKER UNCLASSIFIED9
Design
Maturity
Time
100%
Improved overall maturity
Novel design solutions
Traditional
(labor driven)
Information
driven
Product development process
Fast design maturity
Improved overall maturity, compliancy, change integration and controllability
Innovatie in engineering bij Fokker

10. FOKKER UNCLASSIFIED
New Design - Build
Incremental
design
Product development process
Product 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.
Innovatie in engineering bij Fokker10
RC Cost
fixed
Time
Information
driven
100%
100%
Traditional
(labor driven)
Information
driven
80%
20%

11. FOKKER UNCLASSIFIED
High level architecture of Front Loading
Focus on both complexity and lead time reduction
11
complexity transfer /reduction
lead time gain due to simplicity
Innovatie in engineering bij Fokker
1
2
3
4

12. FOKKER UNCLASSIFIED
Impact on way of working & organizational set-up
Technical and social impact
12
• 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 STATE
Rudder 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

13. FOKKER UNCLASSIFIED
Rudder-in-a-Month
Ambition / 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.
13 Innovatie in engineering bij Fokker

14. FOKKER UNCLASSIFIED
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
14 Innovatie in engineering bij Fokker

15. FOKKER UNCLASSIFIED
Rudder-in-a-Month development
Initial scope (2014) – Hinge definition
Current scope (2015) – Torsion box
15 Innovatie in engineering bij Fokker

16. FOKKER UNCLASSIFIED
RiaM 2014 – Project description
Innovatie in engineering bij Fokker16

17. FOKKER UNCLASSIFIED
RiaM 2014 – Use case 1
Evaluate 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.
17 Innovatie in engineering bij Fokker

18. FOKKER UNCLASSIFIED
RiaM 2014 – Use case 1
Evaluate a hinge connection design
18 Innovatie in engineering bij Fokker

19. FOKKER UNCLASSIFIED
Conclusions
19 Innovatie in engineering bij Fokker
• 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