Jan Verbeek, ADSE

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New 0Supply Chains, New Manufacturing Techniques.

New Aerospace Education?

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Jan Verbeek, ADSE

  1. 1. New supply chains, new manufacturing techniques New aerospace education?? Jan Verbeek Amsterdam, 16 april 2010
  2. 2. ADSE introduction <ul><li>Independent consulting and engineering company, founded in 1996, focused on: </li></ul><ul><ul><li>Design integration and certification </li></ul></ul><ul><ul><li>Complex system development processes, including industrialisation and life cycle support </li></ul></ul><ul><li>80 employees and extensive network for additional services </li></ul><ul><li>Active in: </li></ul><ul><ul><li>Aerospace industry & Air Transport, </li></ul></ul><ul><ul><li>Defence </li></ul></ul><ul><ul><li>Infrastructure & Rail transport </li></ul></ul>
  3. 3. Our World Aerospace – example projects
  4. 4. <ul><li>More and more people want to fly </li></ul><ul><ul><li>Growth of economies in Asia, Brazil, Middle East, Africa </li></ul></ul><ul><ul><li>Global business </li></ul></ul><ul><ul><li>Leisure </li></ul></ul><ul><li>Air transport has become a commodity </li></ul><ul><ul><li>Double digit growth in China, Emirates </li></ul></ul><ul><ul><li>Low cost operators in US, Europe, Asia </li></ul></ul><ul><ul><li>Global Airline Alliances </li></ul></ul><ul><ul><li>Global networks </li></ul></ul>People want to fly
  5. 5. Limitations to further growth <ul><li>Cost of aircraft and services </li></ul><ul><li>Fuel availability </li></ul><ul><li>Safety </li></ul><ul><li>Environmental impact </li></ul><ul><li>Competition </li></ul><ul><ul><li>High speed trains </li></ul></ul><ul><ul><li>Video conferencing </li></ul></ul><ul><ul><li>Internet </li></ul></ul>
  6. 6. Challenges to aerospace suppliers <ul><li>Aerospace suppliers (OEM’s and supply chain) have to offer solutions which meet </li></ul><ul><ul><li>Increasing customer demand for innovations on aircraft </li></ul></ul><ul><ul><ul><li>Reduced fuel burn </li></ul></ul></ul><ul><ul><ul><li>Alternative fuels </li></ul></ul></ul><ul><ul><ul><li>Improved economics </li></ul></ul></ul><ul><ul><ul><li>Further improved safety </li></ul></ul></ul><ul><ul><ul><li>Reduced environmental impact </li></ul></ul></ul><ul><ul><li>& Services </li></ul></ul><ul><ul><ul><li>Sales financing </li></ul></ul></ul><ul><ul><ul><li>Reduced and guaranteed power by the hour cost </li></ul></ul></ul><ul><ul><ul><li>Residual value management </li></ul></ul></ul><ul><ul><ul><li>Local return through offset obligations in production </li></ul></ul></ul>
  7. 7. Challenges to aerospace suppliers <ul><li>But industry also has to make profits </li></ul><ul><ul><li>Reduce cost to maintain or improve margins </li></ul></ul><ul><ul><li>Control and reduce time to market </li></ul></ul><ul><ul><li>Leverage buying power </li></ul></ul><ul><ul><li>Seek economy of scale, through global sourcing </li></ul></ul><ul><li>This means </li></ul><ul><ul><li>Offering real functional solutions </li></ul></ul><ul><ul><li>Reducing development and production cost </li></ul></ul><ul><ul><li>Improving the time to market capability of the supply chain </li></ul></ul><ul><ul><li>Closing gaps in the supply chain </li></ul></ul><ul><ul><ul><li>Capability </li></ul></ul></ul><ul><ul><ul><li>Cultural </li></ul></ul></ul>
  8. 8. Challenges to aerospace suppliers <ul><li>So concluding: aerospace manufacturers: </li></ul><ul><ul><li>Have to introduce new technologies </li></ul></ul><ul><ul><ul><li>and </li></ul></ul></ul><ul><ul><li>Continuously optimize their supply chain </li></ul></ul><ul><ul><ul><li>while </li></ul></ul></ul><ul><ul><li>Achieving maximum process control </li></ul></ul><ul><li>They need to explore unknown territory and deploy innovations in a controlled way </li></ul>
  9. 9. Aircraft design and technology <ul><li>Continuing trade off’s between step changes or incremental developments </li></ul><ul><li>For new aircraft programs </li></ul><ul><ul><li>Optimized metal or fully composite airframes, hybrid interfaces? </li></ul></ul><ul><ul><li>New power plant concepts, using new (bio-)fuels? </li></ul></ul><ul><ul><li>Blended Wing Bodies or other aerodynamic features (winglets, slender wings)? </li></ul></ul><ul><ul><li>All electric aircraft systems? </li></ul></ul><ul><ul><li>More integrated avionics? </li></ul></ul><ul><ul><ul><li>ATC systems, on board systems (vehicle control and IFE) </li></ul></ul></ul><ul><ul><ul><li>Smart structures, built in diagnostics/health monitoring systems </li></ul></ul></ul><ul><ul><li>Highly modular cabin systems? </li></ul></ul>
  10. 10. Aircraft design and technology <ul><li>For aircraft with enough program life (now and later) </li></ul><ul><ul><li>B737, A320, B777, A330, CRJ, F100? </li></ul></ul><ul><ul><li>A380, ERJ series </li></ul></ul><ul><ul><li>B787, C-Series, MJET, A350 </li></ul></ul><ul><li>Continuous and/or mid life updates and retrofits? </li></ul><ul><ul><li>Re-engining? </li></ul></ul><ul><ul><li>Cabin upgrades? </li></ul></ul><ul><ul><li>Cockpit upgrades? </li></ul></ul><ul><ul><li>Etc </li></ul></ul>
  11. 11. Production technology <ul><li>Airframe and Final Assembly </li></ul><ul><ul><li>Composite manufacturing: fibre placement/RTM/thermoplastics? </li></ul></ul><ul><ul><li>Machining vs bonding vs sheet metal assembly for metal airframes? </li></ul></ul><ul><ul><li>[Stuffed] components, smart structures? </li></ul></ul><ul><ul><li>Robot assembly, process automation (24/7 operations, paperless factory?? </li></ul></ul><ul><li>Systems: </li></ul><ul><ul><li>Modular/miniaturized avionics, smart sensors? </li></ul></ul><ul><ul><li>Electric actuators, composite gears, new engine materials? </li></ul></ul><ul><li>Cabin: </li></ul><ul><ul><li>Systems integration into modules (customization like in cars)? </li></ul></ul>
  12. 12. P rocess improvements <ul><li>Seamless CAE/CAD/CAM/CAI/CAT ? </li></ul><ul><ul><li>Computer Aided Simulation/Analysis </li></ul></ul><ul><ul><li>3D Digital Mock Up </li></ul></ul><ul><li>3D Model Based Definition used in production? </li></ul><ul><ul><li>No more 2D drawings </li></ul></ul><ul><li>One tool for Configuration Management during development from requirements to certification (V&V) and rest of program life cycle or connected “islands”? </li></ul><ul><li>Lean/6 sigma for in process control by improved accuracy or built in tolerances in design? </li></ul>
  13. 13. Supply chain developments <ul><li>Integrators reduce their in house manufacturing </li></ul><ul><ul><li>Sell off internal 1st tiers and manufacturing plants? </li></ul></ul><ul><ul><li>Provide local return through local production? </li></ul></ul><ul><ul><ul><li>First parts and subassemblies, </li></ul></ul></ul><ul><ul><ul><li>Later also stuffed components and FAL? </li></ul></ul></ul><ul><li>Global sourcing and extended enterprises </li></ul><ul><ul><li>New 1st tier partners (ongoing consolidation)? </li></ul></ul><ul><ul><li>Global specialist 3rd and 2nd tiers? </li></ul></ul><ul><ul><li>Outsourcing to low cost countries! </li></ul></ul><ul><ul><li>Supplier development (1st and 2nd tier in delegated authority)?? </li></ul></ul><ul><ul><li>Framework contracts covering critical materials like CFRP, Ti? </li></ul></ul>
  14. 14. Supply chain developments <ul><li>Forcing one set of company specific methods/ICT-tools on the supply chain or global standardization or islands and interfaces? </li></ul><ul><ul><li>Q? CM? Certification? </li></ul></ul><ul><ul><li>Project/program Management? </li></ul></ul><ul><ul><li>CAD? </li></ul></ul><ul><ul><li>PDM? </li></ul></ul><ul><ul><li>ERP/MES? </li></ul></ul><ul><li>Bridging capability and cultural gaps? </li></ul><ul><ul><li>Supplier development and help desk function to implement the Extended Enterprise? </li></ul></ul><ul><ul><li>Cross cultural training? </li></ul></ul>
  15. 15. New aerospace education? <ul><li>Businesses have to further develop the capabilities of their employees </li></ul><ul><ul><li>Develop existing people and teams </li></ul></ul><ul><ul><li>Select, train and develop new people </li></ul></ul><ul><li>Developing </li></ul><ul><ul><li>Knowledge </li></ul></ul><ul><ul><li>Skills </li></ul></ul><ul><ul><li>Behavior </li></ul></ul><ul><li>Educators (from schools, universities and business) will have to develop the people needed </li></ul>
  16. 16. New aerospace education! <ul><li>There is an increasing demand for more integrators (mix of technical, commercial, organizational, cultural)!!! </li></ul><ul><li>But not at the expense of real, in depth specialists! </li></ul><ul><li>People who can: </li></ul><ul><ul><li>Innovate, develop and certify </li></ul></ul><ul><ul><ul><li>Products & Systems </li></ul></ul></ul><ul><ul><ul><li>Processes and organizations (Design, Production, Maintenance & Support) </li></ul></ul></ul><ul><ul><li>Assure Quality throughout the supply chain </li></ul></ul><ul><ul><ul><li>Production </li></ul></ul></ul><ul><ul><ul><li>Also including D&D responsibilities </li></ul></ul></ul><ul><ul><li>Manage businesses, department, programs and projects in a global commercial setting </li></ul></ul>
  17. 17. New aerospace education! <ul><li>Education therefore has to cover the following hard core Aerospace Technology subjects </li></ul><ul><ul><li>Design, development, certification of </li></ul></ul><ul><ul><ul><li>Aircraft, airframe components </li></ul></ul></ul><ul><ul><ul><li>Aircraft systems </li></ul></ul></ul><ul><ul><ul><li>Power plant </li></ul></ul></ul><ul><ul><ul><li>Payload systems </li></ul></ul></ul><ul><ul><ul><li>Etc </li></ul></ul></ul><ul><ul><li>Processes & Materials </li></ul></ul><ul><ul><li>Industrial process development </li></ul></ul><ul><ul><ul><li>Manufacturing, assembly & test, quality, logistics processes </li></ul></ul></ul><ul><ul><ul><li>Design for Manufacturing & Assembly (..& RAMS) </li></ul></ul></ul><ul><ul><ul><li>Industrialization (from specification to deployment) </li></ul></ul></ul><ul><ul><ul><ul><li>Plants, Machines and equipment, Tooling, Process automation </li></ul></ul></ul></ul>
  18. 18. New aerospace education! <ul><li>And also cover the following Aerospace Process & Organization (both hard core and soft skill) issues </li></ul><ul><ul><li>Project and program management </li></ul></ul><ul><ul><ul><li>Design & development, industrialization, ramp up, series production/continuous improvement </li></ul></ul></ul><ul><ul><li>Financial (cost estimating, cost/schedule control, value engineering) </li></ul></ul><ul><ul><li>Management of professionals (HR) </li></ul></ul><ul><ul><li>Work in teams (internal, international, global) </li></ul></ul><ul><ul><ul><li>That work together </li></ul></ul></ul><ul><ul><ul><li>Respect different cultures </li></ul></ul></ul><ul><ul><ul><li>And find ways to make things work </li></ul></ul></ul>
  19. 19. New aerospace education! <ul><li>This will have an impact on basic aerospace education </li></ul><ul><ul><li>Technology knowledge and project management skills are starting points </li></ul></ul><ul><ul><li>All other aspects mentioned also need to be addressed in depth!! </li></ul></ul><ul><ul><ul><li>In a specific Aerospace way </li></ul></ul></ul><ul><ul><ul><li>But shared with/copied and translated from other industries </li></ul></ul></ul><ul><li>There is also demand for life long learning programs </li></ul><ul><ul><li>To share experiences and best practices </li></ul></ul><ul><ul><li>To deepen insights and know why </li></ul></ul><ul><ul><li>To build global communities of skilled and experienced people </li></ul></ul>
  20. 20. New aerospace education!!! <ul><li>People that help </li></ul><ul><li>explore unknown territory </li></ul><ul><li>and </li></ul><ul><li>deploy innovations, </li></ul><ul><li>always in a controlled way !! </li></ul>

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