Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview

Presentation title | Sub-title
Month YEAR | Meggitt proprietary and confidential | No unauthorized copying or disclosure
AVIATION INDUSTRY CASE STUDIES
BOEING
GE AVIATION
BAE SYSTEMS
AIRBUS
1

COMPLEX PROBLEM SOLVING METHODS IN ADVANCED RESEARCH &
TECHNOLOGY, PRODUCT AND PROCESS DEVELOPMENT
TRIZ (A SYSTEMATIC INNOVATION
METHODOLOGY) IN THE AVIATION, AEROSPACE
AND DEFENSE INDUSTRY
Property of The Strategy + Innovation Group

EXAMPLE:
Source: Don Masingale, Boeing

4
3/18/09
TRIZ @ GE TRIZ Con 09
GE Energy’s focus on Innovation
The increased innovation focus was placed on the existing Six Sigma quality
organization.
Key objectives:
• Identify current methodologies and tools to boost innovation
• Identify innovation based cost and benefits
• Tie innovation methods with existing quality toolset
• Identify realistic innovation metrics
• Identify which organizations within GE Energy would benefit the most from
expanded innovation based training
Findings:
• GE’s Six Sigma training material currently include discussions on
Brainstorming, Six Thinking hats, and TRIZ methodologies
• TRIZ had been used in the recent past at GE Plastics and GE Aviation
• Several GE Employees had prior training in TRIZ from outside organizations
and prior employers
Source:

5
3/18/09
Identifying Opportunities for TRIZ
TRIZ was selected for future research based on past successes and a high
opportunity for six sigma integration
First efforts focused sharing current employee knowledge, external training
classes, an exploration of existing software tools, & the use of consulting
services.
The second phase focused on a wider level of training of individuals and
teams in Classical TRIZ techniques, and less emphasis on software based
tools.
Training approaches:
Instructor led classes – individuals working on a mixed set of problems
Team event – Workout and TRIZ – teams working on a single problem
Source:

6
3/18/09
TRIZ Based Events
Problem solving efforts
Individual and team based training:
• Component designs
• System design
• System integration
• Root Cause Analysis
Technology forecasting efforts:
• External technology integration
• Market based product offerings
• LEAN six sigma integration
• New product development
Source:

7
3/18/09
BusinessWeek Article Overview1
‘GE scientists hope to avoid costly mistakes down the line. "Conceptual design is
a vital step," says Michael Idelchik, vice-president for advanced technology at GE
Global Research. "If you start with an elephant, no matter how you optimize it
later, you'll never have a giraffe.“’1
• GE uses TRIZ at the front end of the innovation process.
• GE is working with GEN3 Partners.
• Over 382 GE employees in 70 teams have completed the training, as of 2008
TRIZ implementation benefits:
• Under GEN3's tutelage, GE found technology in the radar industry for use in
its next-generation MRI machines
1. Hamm, Steve (2008) Tech Innovations for Tough Times - BusinessWeek, Retrieve on 1/20/09 from
http://www.businessweek.com/print/technology/content/dec2008/tc20081223_490913.htm
Source:

8
3/18/09
Interview with Michael Idelchik on TRIZ
Ask presenter to provide MP4 video
Source:

9
3/18/09
TRIZ at Other GE Businesses
Expanded interest in TRIZ noted at leading industrial business:
• Aviation
• Appliances
• Medical
• GRC
TRIZ based business approaches may complement existing innovation tools at non-industrial
based business.
• Market based innovation tools
• Voice of Customer
After US based TRIZ launch, a global expansion of training and intra-business
communication was implemented:
• Training efforts launched at GE sites in Europe and Asia
• Internal websites support TRIZ based reference materials and practitioner based
communications
Source:

• Next generation submarines
• Weapons systems
• Escape systems from submarines
• Aircraft training systems optimum locations
• Location of airports in remote locations
• Management of airports
• Design of aircraft components
• Persuading UK Government to change/clarify the
regulations for aircraft maintenance for Royal Air Force
10
TRIZ Applied across Different Technologies
Large TRIZ Deployment: 1000++ BAE Systems’ Engineers trained
Source: Oxford Creativity website

Month YEAR | Meggitt proprietary and confidential | No unauthorized copying or disclosure11
Example: #1
1999 – Regional Aircraft Cabin Air Quality
Won the BAE Systems
Chairman’s Innovation award

Example: #2
1999 – Future Strategic Tanker Aircraft
Also won the BAE Systems
Chairman’s Innovation award

Example: #2
1999 – Future Strategic Tanker Aircraft

Problem Background:
▪ Airbus and BAE conducted a TRIZ workshop in Filton,
just outside of Bristol in the UK, to solve the problem
of measuring acoustic emissions
▪ During flight testing of a commercial aircraft wing
there is a requirement to measure acoustic emissions
while the aircraft is in flight. The measurements are
required to be very accurate, however there are
constraints imposed by the testing environment, which
make the use of accurate sensors difficult. In
particular, the test aircraft imposes a restriction on the
weight and volume of the test equipment that can be
used.
14
Example #3
THE MEASUREMENT OF ACOUSTIC EMISSIONS IN A FLYING AIRCRAFT WING
Two possible approaches had been previously considered (but deemed unfeasible):
1. An electrical sensor was available. This was an excellent system that provided the
required accuracy, however it was too heavy to be used in flight.
2. A much lighter optical sensor was also available; however this did not provide sufficient
accuracy.

▪ Problem Solving Constraint: Desirable output/characteristic that we need (in
this case measurement accuracy) that is associated with something harmful,
costly or unwanted (in this case, weight).
− In the language of TRIZ we call this a contradiction.
15
▪ Problem Statement: As we try to
improve one parameter (accuracy) the
other (weight) becomes worse, and
vice versa.
Example #3

▪ Solution Direction: We want a sensor solution that has BOTH good accuracy AND good (which, in
this case, means low) weight.
− In this case the BAE/Airbus team identified two Technical Contradictions.
− We want a sensor that is accurate but we don't want it to be heavy. For this contradiction
we could ask why is it heavy – the answer may be to get enough power - this suggested the
possibility of another type of contradiction in the problem:
− We want a sensor that is accurate but we don't want it to require lots of power.
▪ The Airbus/BAE team identified both these Technical Contradictions:
16
Example #3

Example #3

Example #3
Property of The Strategy + Innovation GroupSource: Oxford Creativity website

Final Solution: derived from principle #32 Colour Change was to use of
an electro-chromatic material to convert the signal from the electric
sensor into a color change, that could be interrogated by an optical fibre.
The team was able to quickly identify a suitable material that was already
being used for adaptive camouflage applications.
20
Example #3

An air force has a requirement for the SRES (note: fictitious acronym to preserve
identity of restricted information) to all aircraft.
▪ The SRES system consists of various units and antennae along with associated
wiring and cooling provisions where necessary. However, for the sake of this TRIZ
exercise/demonstration, we are only looking at the cooling duct that supplies low
pressure/low temperature air to the SRES and PS (Power Supply) units installed
within an equipment crate. This new duct ‘taps’ cooling air from the existing plenum
chamber* attached to the rear of the crate (via a newly introduced cut-out).
21
Airforce SRES Ducting Design
▪ Earlier development activities and ECS
(Environmental Control system) testing have
previously been carried out to arrive at the
development solution shown below (Figures 1
& 2) from which the Design department have
been tasked with creating a ‘production’
solution.
Example:#4

Problem Statement/s:
1. The duct parts comprise of many fabricated aluminum alloy parts welded together, with the
welding is dressed out at critical locations. This is a very labour intensive / costly method to
manufacture with a lot of tooling.
22
Example:#4
2. Both duct parts are rigid. Consequently, it is imperative
that these duct parts are perfectly aligned in order to
prevent a build up of stresses when assembled. Due to
aircraft build differences, design would need to impose
controls such as close manufacturing tolerances on the
duct parts, use of packing/shim and possibly further
(costly) tooling for use at the installation stage.
3. At Stage 1, failure of the clamping force exerted by the
Clamp Ring may lead to loss of cooling air to the main
computer.
4. Disassembly/assembly of the Clamp Ring would be
awkward at Stage 2 due to limited access as the Zone 12
crate would be fitted in the aircraft. Risk of FOD (foreign
object damage).

Example:#4
System Modelling and
analysis:

Multiple Proposed Solutions: Solution PC1a – (3)(30)
Fasten (e.g. rivet) a flexible rubber sleeve to the open end of the Stub Duct. The Sealing
Cap/SRES Manifold Duct can slide into the sleeve and be secured using some kind of
clamp, tie-wrap, Jubilee clip, etc.
Example:#4

Multiple Proposed Solutions: Solution PC1b – (7)(30)
Have Sealing Cap/Manifold Duct slide into the Stub Duct and use a wiper type seal to take
up any duct misalignment.
Example:#4

Multiple Proposed Solutions: Solution PC1c – (30)
Thin membranous flaps bonded on inside of Stub Duct. The intention is that the airflow
through the duct will lift the flaps outwards to seal against the inside of the SRES Manifold
Duct.
Example:#4
Note: TRIZ encourages us
to look for all resources
available to us and make
use of them when possible;
in this case, we are making
use of the ‘air-flow’
resource.

Multiple Proposed Solutions: Solution PC1d – (24)(30)
Fit an intermediary rubber-type bellows type sleeve to fit between duct flanges.
Example:#4

Multiple Proposed Solutions: Solution PC1e – (30)
Seal duct joint using standard adhesive ‘duct-tape’ wrapped around the joint area.
Example:#4

Multiple Proposed Solutions: Solution TC1a – (35)(28)
Elasticated sleeve fitted over joint area rather than a stiff Clamp Ring.
Example:#4

Example:#4
Multiple Proposed Solutions: Solution
TC1b – (31)(28)
Omit the Clamp Ring and compress a
porous rubber section into the joint area
of the ducts that seal on assembly. Any
duct mis-alignment would still allow air to
pass through with minimal loss.

Example:#4
Multiple Proposed Solutions: Solution TC1c – (40)(28)
Replace the Clamp Ring for a neoprene impregnated nylon moulded sleeve that can be
secured to each duct end by means of tie-wraps or Jubilee clips..

Example:#4
Multiple Proposed Solutions: TC2
By cross referencing ‘Loss of
Substance’ against ‘Stress’ on the
Contradiction Matrix, it is suggested
that we look at the following
Inventive Principles:
(3) Local Quality
(36) Phase Transition
(37) Thermal Expansion
(10) Prior Action
Solution TC2a – (3)
Investigate additive layer
manufacture (ALM) hard plastic duct
body blending into flexible rubber
sleeve in joint area. Secure with tie-
wrap or Jubilee clip...

Example:#4
Multiple Proposed Solutions:
Solution TC2b – (37)
Heat-shrink sleeve fitted over
joint area. [See TC1a].
Solution TC2c – (10)
Introduce use of packers,
laminated shim, floating anchor
nuts (at interface of SRES
Manifold Duct with Rack
Assembly) to eliminate any
mismatch in duct alignment (and
thus stress).

Example:#4
Multiple Proposed Solutions: Solution TC2d – (10)
Ensure SRES Stub Duct and Manifold Ducts are positioned accurately during fitment to
the crate by making use of tooling fixtures.

Example:#4
Multiple Proposed Solutions: TC3
The Function Analysis also shows inherent technical contradictions within the SRES Manifold
and SRES Stub Duct parts. Although both are doing their intended function of containing the
airflow, they are very difficult to manufacture and therefore costly (i.e. the ducting is of a
complex shape and is made up of many intricately shaped/folded sheet metal components
welded together).
Extracting the first technical contradiction of ‘Shape’ versus ‘Ease of Manufacture’ we are
guided into looking at the following Inventive Principles:
(17) Another Dimension
(32) Color Change
(1) Segmentation
(28) Replace Mechanical System

Example:#4
Multiple Proposed Solutions: Solution TC3a – (1)
Manufacture the duct part in layers using glass-fibre or carbon fibre rather than by fabrication.

Example:#4
Multiple Proposed Solutions: TC4 Following on from TC3, the other technical contradiction
we can explore is ‘Shape’ versus ‘Productivity’. Note: the ‘Productivity’ parameter is the
closest we can find that captures the ‘cost’ element we are interested in. The Contradiction
Matrix reveals the following Inventive Principles:
(17) Another Dimension
(26) Copying
(4) Discarding and Recovering
(10) Prior Action
Solution TC4a – (10)(34)
Manufacture duct parts using a
‘lost-wax’ casting process.

Example:#4
The Final Solution: Combining the benefits of a selection of solution ideas, we arrive at the
following final solution:

Example:#4
The Final Solution:
Key Messages: Multiple suggested solutions from using TRIZ to solve a tough design and process problem.
TRIZ is a great tool to compliment DFM/A methods. TRIZ is like Differential Equations as a tool for problem
solving. Combining potential solutions usually results in the strongest solution that is adopted and implemented

VALUE OF TRIZ
Confidential | The Strategy + Innovation GroupProperty of The Strategy + Innovation Group
MANY OF THE AVIATION – AEROSPACE - DEFENSE INDUSTRY OEM’S USE TRIZ
TO HELP IN;
» PRODUCT DEVELOPMENT, R&D AND PROCESS IMPROVEMENT EFFORTS, COMPLIMENTING
LEAN AND SIX SIGMA METHODS
INVENTIVELY SOLVING EXISTING PROBLEMS
INCREASING COMPLEXITY REQUIRES INNOVATION AS A COMPETENCY TO ENSURE
HIGH LEVELS OF FUNCTIONALITY, QUALITY AND PERFORMANCE FROM DESIGNS AND
PRODUCTION PROCESSES
INNOVATION IS RISKY AND EXPENSIVE (RANDOM TRIAL & ERROR), YOU NEED
BETTER WAY THAN JUST BRAINSTORMING AND RELYING UPON TALENT ALONE
PLANNING AND PROBLEM AVOIDANCE
TRIZ CAN OBJECTIVELY BE USED TO EVALUATE THE WINNING POTENTIAL OF
SOLUTIONS BEING CONSIDERED
PREDICTING THE EVOLUTION OF TECHNOLOGY
TRIZ CAN PREDICT THE EVOLUTION OF TECHNOLOGY
INCREASING THE VALUE OF THEIR PATENT PORTFOLIO AS PROTECTABLE IP
» MORE PATENTABLE INVENTIONS THAT ARE OUT-OF-THE-BOX

While at Intel he created two US patents, and achieved certifications as a TRIZ Expert (Level3/5), DFSS /
LSS Greenbelt. Since 2006 he’s led the Strategy + Innovation Group LLC (S+IG) in deep diving research
into continuous improvement methods and then recombining them with TRIZ and Systematic Innovation
methods in new and unique ways. He has helped assist OEMs and SMEs build innovative core
competencies with his special emphasis on Advanced Complex Problem solving, IP Management Strategies,
Innovation Management frameworks, and creating and leading customized Systematic Innovation Training for
the Fortune 500. He has successfully applied systematic innovation methods, tools and heuristics across
multiple industries: Semiconductor equipment and manufacturing processes | Capital Equipment development
| High-Tech | Electronics | micro-Drilling | Printed Circuit Board Manufacturing | Electronics Component
manufacturing | Aviation | Aerospace | Military | Defense. Rich is the founder, lead researcher, competitive
intelligence analyst and senior strategist for the Strategy + Innovation Group; his motto he shares with
engineers and managers “Effectiveness first, efficiency comes next” Rich holds a BS in Industrial and
Manufacturing Engineering, (a sub discipline within Systems Engineering), and is still deciding on whether or
not to get a PhD in Engineering Management of Technology or behavioral microeconomics. He has been
practicing the art of Bonsai and Japanese gardening for +30 years.
AUTHOR | SNR. MANAGING PARTNER
Richard (Rich) Platt, previously worked as a Program Manager and Senior Instructor
for Systematic Innovation Methods at the Intel Corporation, as a part of a global
innovation initiative training 850+ engineers, technology development, quality, test,
R&D, Intel Fellows, engineering managers and scientists from the US, Europe, Asia
and the Middle East in systematic innovation methods, delivering $212.5M in
ROI. Working at Intel for 10 years in Manufacturing, Operations, R&D, Technology
Development, and IT, Rich was awarded the Intel Manufacturing Excellence Award –
the highest award that one can receive at Intel. He was Intel Corporation’s last
“Innovation Master”.
Confidential | The Strategy + Innovation Group

CONTACT INFORMATION:
Phone #: 503.784.4343
rplatt@aig-hq.com
www.sig-hq.com
"We Make Engineering Cool – Driving Innovation that Works"
"He Who Dares to Disrupt, Wins More”

Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview

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Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview