Speaking at the Lanner predictive simulation conference 2016, Joe Barker from Turbine Surface Technologies demonstrates how the practical use of Lanner simulation software has reduced lead time.

1. T u r b i n e S u r f a c e T e c h n o l o g i e s
Simulation Application & Benefits
Joe Barker
April 2016

2. T u r b i n e S u r f a c e T e c h n o l o g i e s
Introduction & Overview
• Worked in Rolls-Royce Aerospace
for 18 Years.
• Head of Operation & HS&E –
TSTL, based in Annesley.
Presentation Aims
A short presentation outlining Turbine Surface Technologies
and the practical use of simulation to reduce lead time.
Agenda
• Background to the aerospace markets.
• TSTL – History
• Process Overview
• Technology
• TSTL Facility
• Model Construction
• Conclusions and future plans.

3. T u r b i n e S u r f a c e T e c h n o l o g i e s
Turbine Surface Technologies – Aerospace & Lead Time
• Strong growth in Aerospace markets over the next
10 years.
• Airbus A350 & Boeing 787 are at the start of their
product lifecycles.
• Overall markets set to double inside the next 10
years.
• New engines require investment in new technology.
• Cash, Inventory / Lead Time is key to the ability to
invest in new technology.Rolls Royce Trent XWB on wing
Rolls Royce Gas Turbine
Airbus A350 Order Book (Feb 2016)

4. T u r b i n e S u r f a c e T e c h n o l o g i e s
Turbine Surface Technologies - History
• Joint venture company between Rolls-Royce and Chromalloy
– Established August 2000
• Builds on the strengths of both parent companies
– Rolls-Royce innovation of new coatings and strong market
– Chromalloy proven production implementation and knowledge
• Centre of excellence specialising in coatings for gas turbine components located in the
hot gas path section of the engine
– Responsibility to improve the process
– Generate new technology
– Develop people skills to apply this technology to new products
– Establishing operational best practice
• Part of the Rolls-Royce Turbine Components Supply Chain
– Blades and vanes (NGVs)
Ceramic Core
Manufacture
Investment
Casting
Machining Coating
Machining &
Final
Inspection

5. T u r b i n e S u r f a c e T e c h n o l o g i e s
• Power output 10 times higher than a typical family car
• Local gas temperature 200°C higher than alloy melting
point
• Local gas temp ~ 1580°C
• Alloy melting point ~ 1350°C
• Centrifugal force on each blade is equivalent to the
weight of a heavy truck
• Life requirement is 30 000hrs
• About 6 yrs at 14 hrs per day, 5 Million miles between
major services.
• Coatings application has increased from 25%, now on
more than 50 % of ‘hot end’ turbine components
• Unit cost ~£1100 per blade.
• One third of this is coatings cost
Technology – What do we do?

6. T u r b i n e S u r f a c e T e c h n o l o g i e s
Process Overview
EB PVD
Final Age Heat
TreatmentFPI
Shroud Fin
HVOF
Airflow and Lab
Final Inspection
and Dispatch
Receipt and
Preparation
Pt Plating
Heat
Treatment
Aerofoil Film
Cool EDM
Stop-off Blade
Internal
and Shroud
Aluminise

7. T u r b i n e S u r f a c e T e c h n o l o g i e s
Turbine Surface Technologies – Annesley Facility
• Facility opened in 2002
– 90000 sq ft operational and R&D facility
• Highest ever output in 2013 - £47.8m
– Sales doubled in 4 years in response to customer demand
• 2015 output £32m (230 000 parts), Forecast output in 2016 £39.6m
• Currently 360 employees
Pack and Vapour Aluminising Platinum Plating Low Pressure Plasma Spray HVOF / APS EBPVD
Vacuum Heat Treatment Media Finishing Production Laboratory

8. T u r b i n e S u r f a c e T e c h n o l o g i e s
The use of simulation – Why bother?
• Simulation was first considered at TST in 2012.
– Considerable time spent in outlining the model that could be used.
– Overcomplicated – Scope too large.
– Difficulty in obtaining data required to support model.
• Lead time reduction is a key objective for the business & customer.
• Capital investment decisions to reduce lead time require data to support the business cases.
• Operational changes can be prioritised if the impact can be understood.
• Engagement of internal teams and external stakeholders – Management of change.
• Not a substitute for Load & Capacity modelling.

9. T u r b i n e S u r f a c e T e c h n o l o g i e s
The use of simulation – Designing a model
Pt Plating Process
Blasting Masking Drying Tooling Plating Inspection
• Avoid over complication.
• Set the right level of detail. Consider black boxes rather than individual processes.
• Use part families – Simplified design doesn’t need to consider different part number.
• Only consider headcount if this is the constraint to the process.
– Not a substitute to load & capacity modelling.
• Impact of transactional processes / non-standard processes. Leaving these out will simplify the
model but may lead to inaccurate results.

10. T u r b i n e S u r f a c e T e c h n o l o g i e s
The use of simulation – Gathering data
Involve a Balanced Team
Operational Data
Operational sequence – Readily Available
Site input / output data – readily Available
Capacity information – Readily Available
Overall lead time data available
Asset – Failure / recovery times - Available
Headcount information – Available
Issues Experienced
Rework / Rectification / RFT? – Are they all known? Decision not to
include in model.
Operational times used as estimates – How do we know these are
accurate?
ERP Data Available
Maintenance System

11. T u r b i n e S u r f a c e T e c h n o l o g i e s
The use of simulation
Build The Model
Model built by Lanner.
Validate model
Against existing lead time performance against
different product groups.
What to change if initial results don’t match reality?
Scenarios
Understand what questions need to be answered
before the model is constructed. Adapt list during
build phase.
Results
Results show sensitivities of changes rather than an
absolute prediction of lead time.

12. T u r b i n e S u r f a c e T e c h n o l o g i e s
The Benefits
Flow Description Old SLA New SLA Example Components
B01 Aluminise 14 11 BR710, 535E4, Adour, Tay
B02 Pt., Aluminsie, HVOF 21 18 Fleet HPTB
B03 Pt., Aluminsie, HVOF 28 21 T900 IPTB, T1000 IPTB, XWB IPTB
B05 LCBC Pt., PVD, HVOF 28 21 T1000 HPTB, TXWB HPTB, T900 HPTB
V01 Aluminise 14 11 T700 IPNGV
V02 Aluminise, LVPS, APS 28 21 T900 IPNGV, T1000 IPNGV
V03 LCBC Pt., LVPS, APS, PVD 28 21
• Witness simulation model for all coating processes
used to model the art of the possible and the impact
of capital investment, shift patterns, material
standardisation and input patterns.
• SLA Reduction delivered in 2016. Shift Patterns
changed to optimise flow. Other improvements
planned in 2016 BPD.
• Lean training conducted with Production Leaders in
SMED and VSM. This is supported by the use of
video VSM to identify opportunities for lead time
reduction.
• The most complex components have reduced from
SLA’s of 28 days to 21 days.

13. T u r b i n e S u r f a c e T e c h n o l o g i e s
Future Plans
Expanding Business
TSTL Set to grow by 100% in the next 6 years.
Large investment agreed over a 3 year period.
New Technology
Changing the manufacturing process.
Demanding Customers!
Lead time is a key strategic priority
Possible Plans
Use of simulation as a decision making tool. Quantify
the lead time benefit of capital investment.
Detailed smaller scale models to optimise workflow.