Trends in Aerospace Manufacturing
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1 Engineering, Test & Technology Trends in Aerospace Manufacturing Lane Ballard Vice President of Materials & Manufacturing Author, 9/23/2016, Filename.ppt 1
2 Airlines will need 38,000 new airplanes valued at $5.6 trillion Airplane deliveries: 38, New airplane deliveries by region ,000 25,000 20,000 15,000 10,000 5, ,490 Regional jets 7% 26,730 Singleaisle 70% 4,770 Small wide-body 13% 3,520 Medium wide-body 9% 540 Large wide-body 1% Region Airplanes Asia 14,330 North America 7,890 Europe 7,310 Middle East 3,180 Latin America 3,020 Africa 1,170 C.I.S. 1,150 World Total 38,050 8% 19% 3% 8% 3% 38,050 21% 38%
3 Beyond the 1st Century of Aerospace Manufacturing Automated Composite Fab Additive Manufacturing Robotic Assembly 2
4 Industry Realities Industry customers are demanding more for less 4
5 Market Challenges What the Customers Want Safe Affordable Reliable Upgradeable Flexible Performance Environmentally responsible Available 4
6 Challenges & Opportunities Ahead Design for Manufacturing Aerospace needs to leverage broader industry Speed to Market More capability to customers quicker By KUKA Systems GmbH (KUKA Systems GmbH) [CC BY-SA 3.0], via Wikimedia Commons Traveled Risk Concurrency adds risk of rework Modularity Enables Reuse & Customization 5
7 Advanced Materials Top Business Outcomes Safe/Environmental/Ergonomic Processes Robust First Pass Quality High Rate Capability Reduced part count Optimized Weight AND Cost Top Advanced Materials Applications Metallic Alloys Composites Sealants/Paints Ceramics Machining Distortion Co-Cured Horizontal Tail Automated Paint Computational Materials Models Reduced Part Count Robust Seal/Paint Enablers High rate processes Integrated materials modeling, fabrication processing and properties CST Ablative Surface Materials for Extreme Environments Product Performance & Production System Efficiency 6
8 Expanding capability for unitized machined components Advanced modeling/machining technology critical CMI helping Author, 9/23/2016, Filename.ppt 8
9 Automation Innovation Top Business Outcomes Workplace Safety Product and Process Quality Flexibility / Factory Optimization Standardization / Replication Top Automation Applications Drill/Fill Paint & Seal Composite Fabrication Material Movement Enablers Networked Enabled Manufacturing In-Process Inspection TRL AND MRL 777 Fuselage Flex Tracks 737/787 Heatshield Line 787 Aft Robotic Drill/Fill Innovative, Simple, Robust & Cost Effective 7
10 Additive Innovation Top Business Outcomes Speed to Market Enhance Performance Cost Reduction Buy-to-Fly Top Additive Applications Tools Interiors Structural Parts Enablers Certification In-Process Inspection Tooling Metals Polymers Since 2002 more than 50,000 flyaway parts! 8
11 Titanium Additive/Subtractive Innovation Complex to complex machining will continue to grow! Author, 9/23/2016, Filename.ppt 11
12 Manufacturing Analytics & Digital Threads Top Business Outcomes Reduce Test & Evaluation / Rework 50% Affordable Manufacturing First Pass Quality Improved Factory Safety Top Applications Optimized Factory Flow Manufacturing Process Analytics Improved Automation Execution Robust Process & Material Specs Enablers Analytics Advanced Modeling & Simulation Industry Standards Integrated Digital Factory Future Factory Concepts Real-Time Predictive Analytics Computer Vision Production Simulation Highest Impact Cells On-Time Probability Integrated Digital Factory The Complete Picture Process Automation Safety Analytics 9
13 Summary Market challenges and industry realities are driving changes in the way the aerospace industry designs and builds products Cost Speed to market Performance Environment Advances in materials, automation, additive/subtractive manufacturing, and data analytics are leading the changes for the 2 nd century of the aerospace industry 10
14 BR&T Global Consortia UK AFRC Netherlands Germany Canada CRN Japan USA CAMT CALCE AMATS MACCCS UAE SBRC India Singapore LSC ARTC China TSRC CARE Australia RAS Author, 9/23/2016, Filename.ppt 14
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