Taking Virtual Product Development to the Next Level for the Boeing 7E7 Dreamliner Kevin Fowler

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1 Taking Virtual Product Development to the Next Level for the Boeing 7E7 Dreamliner Kevin Fowler Director, Process 7E7 Program

2 Boeing 7E7 Dreamliner passengers 747/777 speed and range capability 2,000-3,000 units required over next 20 years Improved passenger experience Designed for the environment 20% more fuel efficient 2

3 Fuel Efficiency Breakthrough Increasing Reward Fuel consumption per seat 10% 200 SEATS 225 SEATS Current Twins 250 SEATS 275 SEATS 300 SEATS Current Quads 350 SEATS 400 SEATS 450 SEATS 500 SEATS 550 SEATS Advanced Materials Advanced Systems Advanced Aerodynamics Advanced Engines 7E7 Decreasing Risk Fuel consumption per trip 3,000 nmi trip Three-class seating

4 A New Flying Sensation Design features: Wider seats and aisles Quiet Improved humidity and cabin altitude Advanced environmental controls Superior passenger comfort Guiding principles: Honor the passenger Enrich the flying experience 4

5 Program Schedule Airplane Announcement Authority to Offer Customer Commitments Firm Configuration First Flight Certification and Delivery

6 Virtual Product Development Functional Physical Teaming Build Support Objective: Validate Product Requirements are Met Prior to Design Release 6

7 Virtual Product Development Evolution Next Gen 7E7 Physical Build Functional Digital Product Definition Digital Pre-Assembly Digital Tool Definition Transparent DPA Hardware Variability Control Digital Assembly Sequence Design in Context Geometry Based Process Plans Relational Design Factory Simulation Requirements Traceability Logical Pre-Assembly Support Teaming Design-Build Teams Integrated Product Teams Maintenance Simulation Airplane Health Management LifeCycle Product Teams 7

8 Core Process & System Architecture Support Airplane Sales Configuration Functional Design & Analysis Physical Design & Analysis & Configuration Authority Build Design & Analysis Shop Floor Final Assembly Customer Option Definition and management Customer Specific Option Selections Requirements Functional Architecture Function Definition System Definition Interface Management Behavior Analysis Transport Element Routing EBOM Part Definition Structural Analysis Tool Design Knowledge Based Design Standard Parts Dimensional Management Model Based Definition MBOM Plant Design Factory Flow Analysis Geometry Based Process Plan Manufacturing Simulation Producibility Analysis Ergonomic Analysis Build-To Package Delivered to Factory Floor Configurator DOORS IGE-XAO CATIA V5 DELMIA V5 TBD TeamCenter ENOVIA SmarTeam ENOVIA LCA ENOVIA IPD Logical Single Source of Product Data LSSPD Boeing and Partners 8

9 Single Source of Data Enables Integrated Virtual Product Development Aerodynamics Airport Noise Vehicle Stability & Control Vibration & Acoustics Structural Behavior Customer Configurations ENOVIA SmarTeam ENOVIA LCA ENOVIA IPD Logical Single Source of Product Data LSSPD Boeing and Partners Electro Magnetic Effects Production Logistics Cabin Environment Aircraft Systems Variation analysis Maintenance & Repair Factory Simulation Failure Analysis 9

10 Loads Analysis Process Aeroelastic Analysis Solutions V5 Geometry Solution Common FEM External Loads Nastran Loads Mapping Internal Loads Nastran Gages/ Offsets Int. Loads Gages Optimization Nastran Failure criteria Stress Analysis & Data Management 10

11 Integrated Lines, Loads and Laws Design Requirements Baseline Configuration Rapid FEM-Based Sizing Optimized Structural Definition Interfaces Best, Integrated General Arrangement Optimized Aerodynamic Lines Control Laws Aerostructures Lines & Loads Optimization Stability & Control Optimization Vehicle Optimization 11

12 Advanced Aerodynamics Advanced computational fluid dynamics (CFD) Cray super computers and large PC clusters Wind tunnel testing 12

13 Virtual Systems Approach Standalone Modeling And Simulation Systems Level Tests Airplane Level Tests Factory and Flight Tests Real System and Airplane 13 All Simulated Simulated airplane systems Simulated airplane wiring (per ICD) Real airplane systems All Real

14 Virtual Build Optimize Production System Digital Production Reviews Analyze Production Logistics Validate Assemblies Build the 7E7 Virtually 14 Collaborative Global Production System Integrated Build Plan to Mechanics

15 VPD Enabled Learning Curve 1 Dollars 2 Recurring savings 5 5 Traditional Unit Completion 7E7 Unit Completion X X Cycle time reduction Faster investment recovery Time First article is virtual 15

16 The Boeing 7E7 Dreamliner A New Airplane for a New World 16

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