Galorath Annual Conference April Presented by: David Tyso & Martin Dunkley. Design to Cost Engineers. Airbus UK. Winging-it with Seer DFM

Transcription

1 Galorath Annual Conference 2008 April 2008 Presented by: David Tyso & Martin Dunkley Design to Cost Engineers Airbus UK Winging-it with Seer DFM

2 Airbus Airbus single company became operational on 1st January 2001 In October 2006, EADS became sole shareholder Product line ranges from 107 seater A318 to A380 with 525 seats More than 7,000 aircraft orders from 257 customers Turnover of 25.2bn in 2007 with an order book of 283.8bn Employs 57,000 people world-wide Design, component manufacturing and assembly at 16 Airbus sites in the UK, France, Germany and Spain Airbus subsidiary companies in the United States, China, Japan and in the Middle East. Four training centres, five spares centres and 150 field service offices Galorath Annual Conference 2008 April 2008 Page 2

3 This is what we do Galorath Annual Conference 2008 April 2008 Page 3

4 Airbus Product Line ( ) ( nm) Galorath Annual Conference 2008 April 2008 Page 4

5 Industrial Responsibility Galorath Annual Conference 2008 April 2008 Page 5

6 Major Wing Components Front Spar Centre Spar Underside of Skin Panel Ribs Rear Spar Stringers Spoilers Rib Skin Panel Spar Galorath Annual Conference 2008 April 2008 Page 6

7 Programme Phases Product Idea Established Aircraft Concept Selected Detailed Concept Validated Component Design Complete First Flight EIS M0 M2 M3 M5 M6 M7 M8 M9 M11 M13 Feasibility Concept Definition Development Series DtC / Continuous Concept to Cost Design to Cost Improvement Optimisation of the entire A/C as an integrated system under cost target derived from market price Modifications to the initial design of the plane, at the level of a module, a set of parts or a process. Modifications of design features or processes during production stage and operational life of aircraft Make / Buy split set Start of FAL Galorath Annual Conference 2008 April 2008 Page 7

8 Series Production Example Single Aisle Spoiler Composite sandwich structure Carbon epoxy prepreg facesheets Nomex honeycomb cores Aluminium alloy hinges, and actuator fittings mechanically attached to the bond panel. Galorath Annual Conference 2008 April 2008 Page 8

9 Trade Off Studies using DFM Criteria: Use of cost effective, suitable materials and processes Zero mass penalties Two way interchangeable no impact on FAL Equivalent to current spoiler properties, e.g. stiffness Latest JAR requirements Repair techniques are no more intensive than present design Galorath Annual Conference 2008 April 2008 Page 9

10 Trade Off Studies using DFM Re-design investigated with Supply Chain Three Generic Groups Composite Monolithic Composite Sandwich Metallic Galorath Annual Conference 2008 April 2008 Page 10

11 Trade Off Studies using DFM Combinations of compatible Materials & Manufacturing Technologies: Prepreg, Nomex, Re-enforced Foam, Resin Infusion Materials, (Preforms / NCF s), Al Alloy HLU, ATL, LRI, RTM, Filament Winding, Machining Re-location of work Risks Analysis: Materials / Manufacturing / Analytical Tools / Out Sourcing Galorath Annual Conference 2008 April 2008 Page 11

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13 Development / Future Aircraft The world of aircraft manufacturing is changing. Use of Composite material within the airframe is increasing rapidly to meet the Airlines operating requirements Galorath Annual Conference 2008 April 2008 Page 13

14 Current Aircraft Development (Design to Cost) Designs dictated by Technology Readiness of materials, processes and analytical methods. Trade offs look at both metallic, composite and hybrid solutions Detailed analysis of design concepts, studying effects of discrete changes DFM allows for multiple iterations to be completed with only minor changes to the base model Enables detailed costing to be traded off against weight and manufacturability to obtain the optimum solution Identifies opportunities to be developed for future aircraft programs Images show 3 different design / manufacturing solutions for the same piece of structure. Galorath Annual Conference 2008 April 2008 Page 14

15 Future Aircraft Developments (Concept to Cost) The concept phase allows us to explore radical designs within a prelaunch programme phase environment Comparison of alternative and innovative manufacturing technologies / design solutions applied to component families Metallics, CFRP, Hybrid laminates Effect on Cost & manufacturing time with alternative (what if) design solutions Fabricated / machined components Co bonded Integral design DFM allows Quick look to assess impact of design solution Galorath Annual Conference 2008 April 2008 Page 15

16 DFM Way Forward for use in Airbus Airbus now have CAI modules that extends our capability Previously artistic licence required for some operation modelling Specific Aircraft Assembly Modules complements core modules + prior developments in Composite & Metallics Calibration activity launched Enhanced capability to move away from a deterministic approach account for uncertainty & risk One known thing about an estimate is that is wrong, the question is by how much. A move away from Single point (deterministic) estimating DFM is only one of the tools in our current suit Consistent use of Risk Analysis required, leading to a single Risk tool selection DFM is to be linked with this tool. Galorath Annual Conference 2008 April 2008 Page 16

17 Experience on using DFM Likes Easy to account for Production Experience & Part Complexity Accommodates for a level of uncertainty Easy to re-use product structure & include / exclude items Comprehensive Composite & Advanced Machining Modules Can be used straight out of the box (sanity check required) Dis-likes Getting customized ini files quickly installed on servers (internal AUK issue) The use of Cost per Kg to define the price of composite materials in the Composites ini file Understanding how DFM addresses Learning Curves Galorath Annual Conference 2008 April 2008 Page 17

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19 AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS UK LTD. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS UK LTD. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS UK LTD will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks. Galorath Annual Conference 2008 April 2008 Page 19