Aerospace & Defense Manufacturing · PDF fileof data from product design to manufacturing, to...
Transcript of Aerospace & Defense Manufacturing · PDF fileof data from product design to manufacturing, to...
Aerospace & Defense
Manufacturing DigitalizationZvika Weissman, Siemens PLM SW, MFE / Industrial Enterprise Solutions Director
Nicolas Steinier, Sonaca, MFE / MFG Digital Transformation Project
PLM Europe, October 24th, 2017
Realize innovation.Restricted © Siemens AG 2017
Restricted © Siemens AG 2017
2017.10.24Page 2 Siemens PLM Software
Agenda
Our vision for aerospace & defense
The digital twin - innovation
The digital thread - Sonaca
Restricted © Siemens AG 2017
2017.10.24Page 3 Siemens PLM Software
Digitalize your
manufacturing by
leveraging a digital thread
of data from product design to
manufacturing, to create a
digital twin of your
production facilities and
processes.
Digitalize the Product Realization Process
An opportunity for aerospace & defense companies
Type certificate
FCA
CDR
PDR
PRR
Production
certificate
Airworthiness certificate
PCA
Libraries, Templates, Docs
Checklists
SRR
SDRCONCEPT
DESIGN
BUILD
DELIVERREQUIREMENTS
Restricted © Siemens AG 2017
2017.10.24Page 4 Siemens PLM Software
Agenda
Our vision for aerospace & defense
The digital twin - innovation
The digital thread - Sonaca
Restricted © Siemens AG 2017
2017.10.24Page 5 Siemens PLM Software
The Future of Manufacturing
Industrie 4.0 - three key elements
Production network
Flexible value chains with
information available in realtime
across company boundaries
1
Fusion of virtual and real world
Integration of product design and
production engineering for shorter
time to market
2
Cyber-physical systems
Modular production units
with complete and consistent
virtual image
3
Additive
manufacturing
Simulation
Autonomous
robots
Augmented
reality
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Plan Your Future Factory
3Dprint a composite winglet
DESIGN
BUILD
Winglet manufacturing
Wing sub-assembly
Composites Inspection
Wing assembly
Wing paint
Assembly docs creation
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Composite Winglet 3D Printing
A breakthrough is an option!
• Definition of robotic paths, to build-
up the structure.
• Advanced OOTB multi-axis
deposition algorithms for efficient
path planning.
• Material deposition simulation for
thorough process validation.
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Plan Your Future Factory
Inspect the composite parts for deficiencies
DESIGN
BUILD
Winglet manufacturing
Wing sub-assembly
Composites Inspection
Wing assembly
Wing paint
Assembly docs creation
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Ultrasonic Wing Composite Quality Inspection
Virtual commissioning & robotics simulation
• Definition of robotic paths, to include
a pattern of inspection points.
• Complex workcell, which mandates
a PLC to synchronize the devices,
and control safety interlocks.
• Definition of the inter-devices signals
logic.
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Plan Your Future Factory
Attach the wings to the fuselage
DESIGN
BUILD
Winglet manufacturing
Wing sub-assembly
Composites Inspection
Wing assembly
Wing paint
Assembly docs creation
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Wings Assembly (Attachment to Fuselage)
Process & tools validation
• Kinematics definition of all shop floor
tools and jigs.
• Collision avoidance and ensuring
safety distance is kept, while moving
large objects.
• Simultaneous human-tool simulation
enables realistic validation
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Plan Your Future Factory
Paint the airplane
DESIGN
BUILD
Winglet manufacturing
Wing sub-assembly
Composites Inspection
Wing assembly
Wing paint
Assembly docs creation
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Wing Paint
Automate, autonomous…
• Validation of paint and surface
coating processes.
• Robot can be mounted on an
external axis (or AGV).
• Mesh creation for consistent paint
pattern.
• Thickness coverage simulation.
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Agenda
Our vision for aerospace & defense
The digital twin - innovation
The digital thread - Sonaca
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Manufacturing Engineering PLM Project
PLM Connection 2017October 24th
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Agenda
• Company introduction• Teamcenter EcoPLM project• Teamcenter Manufacturing implementation• Training & User adoption• End-to-End Business solution
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COMPANY INTRODUCTION
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SONACA Group extended global footprintSONACA facility
SONACA Space• Thermal Engineering
• CFD
• Manpower :25
Sinelson• Assembly
• Manpower : 60
SONACA Montreal• Long Bed Machining
• Stringer Milling & Forming
• Manpower : 320
SONACA Transilvania• HLU Composite
• Assembly
• Manpower : 50
SONACA Group Headquarters• Engineering - R&D Centre
• Advanced Composite Process
• Machining
• Sheet forming
• Additive Manufacturing (FMAS)
• Complex Assembly
• Manpower :1650
LMI Aerospace• Engineering
• Manpower : 20
LMI Aerospace• Engineering
• Assembly
• Machining
• Sheet forming
• Composite
• Processing
• Distribution
• Manpower : 1750
LMI Aerospace• Engineering
• Manpower : 5
LMI Aerospace• Sheet forming
• Manpower : 70
SONACA Aircraft• JV with TAF
• General Aviation
• 2 seats S200 AC
Sobraer• Engineering
• Assembly
• Manpower : 260
Sopeçaero• Sheet Forming
• Manpower : 85
Pesola• Machining
• Manpower : 50
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SONACA Group is active in five business lines
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D&B
B2PSpace
EngineeringServicesInnovation
Aerostructure “Design & Build”
Aerostructure“Build-to-Print”
Space Applications
Engineering ServicesInnovation
World-class capabilities in development, manufacturing, assembly and certification of aerospace structures for wing movables & complex fuselages
Combination of highly competitive
Manufacturing /Assembly in low cost
countries & state-of-art automated manufacturing
technologies
Advanced structural and thermal
applications for space satellites &
launchers
High-quality, reliable and cost-efficient end-to-end
engineering solutions
Research & Technology activities to develop,
in-house or via strategic partnerships, new business lines
Expertise for all kind of structures (Composite & Metallic)
Flap Box of :
* EMBRAER Legacy500* EMBRAER ERJ175/195 E2
Center Fuselage I of EMBRAER ERJ145
Main Landing Gear Doors of AIRBUS A400M
Wing Slats and Mechanisms of
* All AIRBUS from A310 to A350* EMBRAER ERJ170/190* BOMBARDIER C-Series* DASSAULT F7X
Wing Fixed Leading Edges of
* AIRBUS A400M* EMBRAER ERJ145 * BOMBARDIER C-Series* DASSAULT F7X* LEARJET 85* PILATUS PC24
Flap Mechanism & Fairings :
of EMBRAER ERJ175/195 E2
Nose Upper Shellof AIRBUS A380
Rear Fuselage of :
* EMBRAER Legacy500* EMBRAER ERJ145
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SONACA GROUP DATA MANAGEMENT IS STRUCTURED AROUND 4 KEY
BUILDING BLOCKS COVERING THE END-TO-END AIRCRAFT LIFECYCLE
Design Engineering
Stress Engineering
Config. MgtManufactu-
ring Engineering
Prototype & Certification
Supply Chain & Delivery Mgt
Manufactu-ring
Operations
Design Engineering
Change Management
Program & Quality Management
Program Management system
Supply Chain Data Management system - ERP
• On-time & On-Spec delivery of products• Full respect of NRC envelope w/ PMO Data factory• Design to cost (-12% RC over dvp cycle)
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• Cultural change• Supply chain optimization• Operational excellence
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3
7
8
9
End-to-end aircraft lifecycle
Technical Product Data Management system - EcoPLM
• Decrease of engineering cost (-5% every year)• Faster / Easier impact assessment of modifications• Decrease of IT Opex (-85% compared to 2013)
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5
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©SONACA 2016. All rights reserved. Confidential and proprietary document.
What’s next?...
Integrated Digital Data Management system - Industry 4.0
• Holistic approach, covering entire aircraft life• Pragmatic approach => POC to demonstrate ROI• Deployment driven by business case only
10Connecting domains
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TEAMCENTER ECOPLM PROJECT
Project timeline
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2013 2014 2015 2016 2017 2018 2019
Phase 1 : Design & Change Mgt
Phase 2 : Manufacturing
TC Upgrade
Enhancementpacks
Data Migration
Embraer E2-190 Embraer E2 175
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TEAMCENTERMANUFACTURINGIMPLEMENTATION
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Project Drivers and ChallengesNew paradigme: - 35 production plant’s potentialy involved in a program- More product changes- More flexibilty required
Main driver: Cost reduction
skills and software flexibilityDecrease of obsolescence costs
PLM management of manufacturing objects Technical sheets Tooling definition NC programming Manufacturing repr. (COS)
Manufacturing BOM Engineering BOP Management :
Resources management at operation level
Build the blocks for digital shopfloor
Business Change management for
manufacturing engineering Decrease the dev. leadtime Increase flexibility (skills)
IT Management of heavy CAD
models Performance of the system
Operational Define a global roadmap
MOTIVATION CHALLENGES
Rethinking the project
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Head of Structure, Basic BOM ViewsEngineeringManufacturing
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Manufacturing Definition Dossier (MDD)Basic Item View
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Manufacturing Scenario (1)
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Search from Customer P/N
A day in a life of a manufacturing engineer
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Manufacturing Scenario (2)
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Select engineering structure
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Manufacturing Scenario (3)
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Find the configuration node
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Manufacturing Scenario (4)
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Open the configured structure
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Manufacturing Scenario (5)
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Compare two engineering configurations
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Manufacturing Scenario (6)
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Select the same Part in each configuration
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Manufacturing Scenario (7)
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Graphical compare
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Manufacturing Scenario (8)
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Graphical compare
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Manufacturing Scenario (9)
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Graphical compare
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Manufacturing Scenario (10)
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Select the eBOM and the corresponding mBOM
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Manufacturing Scenario (11)
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Compare eBOM with mBOM
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Manufacturing Scenario (12)
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Find the Manufacturing Dossier (MDD) of the
assembly
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Manufacturing Scenario (13)
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Select the Tooling Definition Dossier (TDD)
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Manufacturing Scenario (14)
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View the Tooling Definition Dossier (TDD)
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Manufacturing Scenario (15)
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Direct view of the tooling specification
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Manufacturing Scenario (16)
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Select the tooling structure
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Manufacturing Scenario (17)
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View the tooling structure
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TRAINING &USER ADOPTION
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Training & User adoption
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Main challenge:• Cultural change since no PLM existing in Manufacturing• Transversal process (Manufacturing engineering,
Configuration, Tooling, NC Programming, Supply chain and Sub-contractor integration)
Training organization for a wide range of skills and across borders (Brazilian Plants)
Collaboration platformfor supports and follow-up
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Training & User adoption
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Adoption monitoring
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END TO END
BUSINESS SOLUTION
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From Digital to Business Transformation
• PLM Project often means Product Management Improvement and Digital Tranformation
ecoPLM Project moved to a Business Transformation for Sonaca by• Rethinking the Development Process • Define the Master Data• Define the new Adoption Strategy • Finally code it into the Software.
Digital Transformation
Business Transformation
Project Management
Master Data Management
Product Management
Master Data Management is the keystone of our Business Transformation betweenProduct & Project Management and nobody can do it for yourself better than you !
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Product Development
Master Data Business Data
Product Management Project Management
Product Management Project ManagementData Management
End to End Business Solutionfor Product (& Process) Development & Modification
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End to End Business Solutionfor Product (& Process) Development & Modification
SonacaMaster Data Mgt
Time Management
Information Mgt
Manuf DB System
ARIS
Ppt
BusinessProcess Mapping
BusinessWork Load Data
Business Resource Data
Eng DB System
Risk Mgt
Cost Mgt
Task Management
Information Mgt
Product Management Project ManagementData Management
Group
Name Name
Skills
Name
Product Development
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Time Managementfor Product (& Process) Development & Modification
To manage End to End Project activities balancing Scope, Time, Cost & Quality
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
KOM PDR CDR Go For Prod FAI HO
Sonaca Product Development Competing Project Constraints
Phase 2
• 3D Models
Phase 3
• 2D Drawings
Phase 2
• Tool Spec.
• Tool Order
• RFQ
Phase 3
• Raw Mat Procurement
• Tool Design
• Tool Manuf
• NC Programs
• Operation Sheets
…
…
…
…
Sonaca Project Activities Steering Schedule
Time Mgt
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Time Management - Report & PM Mgt
Weekly Report to Program Mgt
3. Detailed Projection ahead or behind target(Working Days)
1. Shipset Status (MSN 402)
a. Internal Target (Exw Sona) : 10/03/2015b. Internal Projection : 27/03/2015
c. Customer Target (On Dock) : 08/04/2015d. Customer Projection : 03/04/2015
-13 JO
+1 JO
2. Shipset Short-Term History (MSN 402)
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Time Management & Lines of Business
CPT CPI CPA CPQ
PGM1
PGM2
PGM3
ALL PGM
Tooling
1. Detailed Progress Follow-up (at Part Number Level)2. Work/ Load Analysis3. Aligned Information/Reports from Program Perspective
PGM1 -Steering Schedule Summary
Tooling Tasks Mgt (All PGM)
Steering Schedule Summary – All PGM
Extract
Customer Program WP PoETotal
SlackP T
AIRBUS A330 Slats NEO A330-1795 0 22/07/2016 22/07/2016
A400M OWLEC A400C-0073 90 26/05/2016 17/10/2016
BUSINESS JET F7X FLE F7XF-1452 -3 5/09/2016 31/08/2016
F7X Slats F7XS-1452 -8 12/09/2016 31/08/2016
L500 RF E500RF0061 -14 4/05/2016 14/04/2016
E500RF0085 16 20/01/2017 13/02/2017
PC24 FLE PC24-0102 9 12/12/2016 5/01/2017
EMBRAER E175 E2 Fairings E200FP0006-FAIRINGS -12 3/05/2017 13/04/2017
E175 E2 Flaps FTI-OUTBD -30 6/01/2017 10/11/2016
E200FP0006-INBD -25 3/04/2017 27/02/2017
E175 E2 Slats Test -11 29/06/2016 14/06/2016
E200-S0006 -30 10/04/2017 27/02/2017
E190 E2 Flaps E204-00008 0 18/03/2016 18/03/2016
E204-00005 0 8/05/2016 8/05/2016
E200FP0005 0 22/06/2016 22/06/2016
E190 E2 Slats E204-00004-2 -4 19/04/2016 13/04/2016
E200-S0005 10 21/06/2016 5/07/2016
E204-00004-3 -1 18/07/2016 15/07/2016
SPATIAL MPCV Tank Bulkead FU1 -11 31/03/2016 15/03/2016
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CONCLUSIONS
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SONACA DIGITAL ROADMAP
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Project Management
Master Data Management
Product Management
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
KOM PDR CDR Go For Prod FAI HO
We have found the path and developped a method…
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SONACA MANUFACTURING DIGITAL ROADMAP
68
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Engineering Services
69
SONACA Engineering Services
EngineeringServices