AIRBUS DS LEAN JOURNEY TO ACCELERATE INNOVATION. David Muñoz, Lean Expert Silvia Pascual, Lean Expert October 25 th, 2017
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1 AIRBUS DS LEAN JOURNEY TO ACCELERATE INNOVATION David Muñoz, Lean Expert Silvia Pascual, Lean Expert October 25 th, 2017
2 Contents The Company Enabling Innovation Lean Journey LPD- Case Study Future Challenges 2
3 Airbus We Make it Fly Airbus is the largest aeronautics and space company in Europe and a worldwide leader. 3
4 Airbus Defence and Space Strong, innovative and customer focused Military Aircraft Space Systems Communications, Intelligence & Security Unmanned Aerial Systems Europe s #1 in defence and space with 11.9 bn revenues in 2016 Future-proof strong growth in order intake, an order book above 41.5 bn Investing in growth 332 million spent on R&D in
5 Enabling Innovation 5
6 The Lean Journey Lean Objectives B.II, B.III & B.IV Lean Improvers Hoshin Kanri 80% Visual Management Problem Solving Pilots Kaizen (Business Needs) Lean Objectives B.V Hoshin Kanri alignment with VM >90% Visual Management 30% PPS Kaizen (Top Improvement Priorities) 2017 Extend LPD Lean Innovation Vision & Roadmap Governance Model Buy-in CEO Kick-off sessions Quality Excellence LPD Lean Thinking Lean Routines LPD SBCE NOV Virtual Visual Management Quality Excellence E2E Missions LPD SBCE pilots Lean Network (LE, CA) 50% Visual Management Kaizen pilots (E2E) 100% Visual Management 50% PPS Pilots Quality Excellence Kaizen LPD pilots 6
7 LPD at Airbus DS 7 October 26th, 2017
8 LPD in Airbus DS Best Practice SBCE Time constrains Budget constrains Lack of direct interface with customer Fuzzy requirements Few suppliers available Innovation Agility Adaptability to requirement changes No existing experience in different technologies Regulations 8
9 B0 - Mission Power Gen Selection B1 - Fuel Architecture / Integration (APU & Diesel Eng.) B2a - Intallation / Position B2b - Intallation / Coffin Configuration A4 - Exhaust B5a - Air Supply (Only Diesel Eng. & APU) B5b - MPU Compartment Ventilation / Intake (Only Diesel Eng. & APU) B5c - MPU Compartment Ventilation / Ramps (Only Diesel Eng. & APU) B6a - Ventillation on ground / Diesel Engine B6b - Ventillation on ground / APU A7 - Cooling (Only Diesel Eng. Heat Exchangers) A8 - Cooling electrical generator A9a - Gear box / Supply A9b - Gear box / Regulation B11 - Generators 2xRED-A3 ENGINES 2xTEDS ENGINES 3xCM-300 ENGINES 3xWANKEL ENGINES 4xLYCOMING ENGINES APU P&W 787 Hi-RAT Integrated with the A/C c c c c nc Dedicated Pressurized Zone / Distributed in both Cargo Bays / 2xREDc nc nc nc nc c A3/TEDS ENGINES Pressurized Zone / Distributed in both Cargo Bays / 3xCMnc c nc nc nc c 300/WANKEL ENGINES Pressurized Zone / Distributed in both Cargo Bays / nc nc c nc nc c 4xLYCOMING ENGINES Pressurized Zone / All MPU in one Cargo Bay / c nc nc nc nc c C Compatible 2xRED-A3/TEDS ENGINES Pressurized Zone / All MPU in one Cargo Bay / 3xCMnc c nc nc nc c NC Not compatible 300/WANKEL ENGINE Pressurized Zone / All MPU in one Cargo Bay / nc nc c nc nc c? Unkknown Compatibility, Still under investigation 4xLYCOMING ENGINES Non-Pressurized Zone / CLG Bay / 2xRED-A3/TEDS ENGINES c nc nc nc nc c Option rejected Non-Pressurized Zone / CLG Bay / APU P&W nc nc nc c nc c Non-Pressurized Zone / Belly Fairingz+CLG Bay / 3xCMnc c nc nc nc c 300/WANKEL ENGINES Non-Pressurized Zone / Belly Fairingz+CLG Bay / APU P&W nc nc nc c nc c Non-Pressurized Zone / External / FUS (Hi-RAT) nc nc nc nc c nc Non-Pressurized Zone / External / Wing (Hi-RAT) nc nc nc nc c nc Non-Pressurized Zone / Internal / Hi-RAT nc nc nc nc c nc Simple shared coffin (Diesel Eng.) Independent coffin (Diesel Eng.) c c c nc nc c nc nc nc c c c c nc c nc nc nc nc Simple shared coffin (APU) Independent coffin (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc External Installation (Hi-RAT) nc nc nc nc c nc nc nc nc nc nc nc nc nc nc nc c c c External One unique tube External Several tubes c c c c nc c c c c c c c c c c c nc nc nc c c nc External Air Supply (Diesel Eng.) Cabin Air supply (Diesel Eng.) c c c nc nc c c c c c c c nc c nc nc nc nc c nc nc c External Air Supply (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c Cabin Air supply (APU) Single intake (Diesel Eng.) nc nc nc nc nc nc nc nc nc nc nc nc nc Multiple intake (Diesel Eng.) c c c nc nc c c c c c c c nc c nc nc nc nc c nc nc c c nc Single intake (APU) nc nc nc c nc nc nc nc nc nc nc nc c nc nc nc nc nc nc c nc c nc c Multiple intake (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c nc c Only Ventilation / Actuated ramps nc nc nc nc nc Only Ventilation / Non actuated ramps c c c nc c c c c c c c c c nc nc nc c nc c c c c c c Only Ventilation + Cooling / Actuated ramps c c c nc c c c c c c c c c nc nc nc c nc c nc c c c c Only Ventilation + Cooling / Non actuated ramps c c c c nc c c c c c c c c c c c nc nc nc c c nc c c nc c c c c c Ejectors (Diesel Eng.) nc nc nc nc nc nc nc nc nc nc nc nc Ventilators (Diesel Eng.) c c nc nc c c c c c c nc c nc nc nc nc nc nc c nc c nc nc c c c External source (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c idg sii and : -GearBox interface requirements met -Gear box not including RPM regulation Ejectors (APU) nc nc nc c nc nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c nc c nc nc c c c c c nc nc nc Ventilators (APU) nc nc nc c nc nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c nc c nc nc c c c c c nc nc nc External source (APU) nc nc nc c nc nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c nc c nc nc c c c c c nc nc nc MPU heat exchanger within the coffin - Ambient Air nc nc nc nc nc nc nc nc nc nc nc nc nc nc MPU heat exchanger out of the coffin c c c nc nc c c c c c c c c nc c nc nc nc nc c c nc c c c nc c c nc nc c c c c c c c nc nc nc MPU heat exchanger within the coffin - Cabin Air Shared with MPU c c c nc nc c c c c c c c c nc c nc nc nc nc c c nc c c c nc c c nc nc c c c c c c c nc nc nc c c Dedicated MPU Supply c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c c c c nc nc nc c c c Independet nc With regulation (variable multiplication) nc Without regulation (fixed multiply) c c nc nc c c c c c c nc c nc nc nc nc nc nc c nc c nc nc c c c c c nc nc nc c 115 VFG (Diesel Eng.) c c nc nc c c c c c c nc c nc nc nc nc nc nc c nc c nc nc c c c c c nc nc nc c 270 VDC (Diesel Eng.) nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc 115 CFG (Diesel Eng.) c c c nc nc c c c c c c c nc c nc nc nc nc c nc nc c c nc c c nc nc c c c c c c nc nc nc c c c c c 230 VFG (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c nc c nc nc c c c c c c nc nc nc c c c nc nc nc nc nc 115 V (Hi-RAT) nc nc nc nc c nc nc nc nc nc nc nc nc nc nc nc c c c nc nc c nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc LPD in Airbus DS Best Practice The process Scoping VoC T/O & Open Points Convergence Planning Convergence Trade Offs reviews Trade offs Trade-offs Kepner Selected Name KT Result Rationale ID Tregoe Solution - maintainance easier A7 Cooling Yes Alternative B B (out of coffin) - less wight - achieve performance Mission Power A0 Yes Alternative C A (RED) - less technical risk Generator selection - certified - centered C (FWD Cargo B2a Location Yes Alternative C - less weihgt (compacted) Bay) -less complexity (compacted) - Simplicity B5b Ventilation intake Yes Alternative B B - less weight and cost - less aerodinamics impact - Simplicity Compartment B5c Yes Alternative B B - less weight and cost ventilation ramps - mantainance INCOMPATIBILITY MATRIX Justification (Action carried out, Dependencies ) A330 AWACS Mission Power Generation Last update: 28th November 2016 Pendiond resistance estimation To be considered as añternatives: - LYCOMING (possible extra cost) - TEOS (high risk) Review A solution A solution can also be considered 2xRED-A3 ENGINES 2xTEDS ENGINES 3xCM-300 ENGINES 3xWANKEL ENGINES B0 - Mission Power Gen Selection 4xLYCOMING ENGINES APU P&W 787 Hi-RAT Integrated with the A/C B1 - Fuel Architecture / Integration (APU & Diesel Dedicated Eng.) Pressurized Zone / Distributed in both Cargo Bays / 2xRED- A3/TEDS ENGINES Pressurized Zone / Distributed in both Cargo Bays / 3xCM- 300/WANKEL ENGINES Pressurized Zone / Distributed in both Cargo Bays / 4xLYCOMING ENGINES Pressurized Zone / All MPU in one Cargo Bay / 2xRED-A3/TEDS ENGINES Pressurized Zone / All MPU in one Cargo Bay / 3xCM- 300/WANKEL ENGINE Pressurized Zone / All MPU in one Cargo Bay / 4xLYCOMING ENGINES B2a - Intallation / Position Non-Pressurized Zone / CLG Bay / 2xRED-A3/TEDS ENGINES Non-Pressurized Zone / CLG Bay / APU P&W Non-Pressurized Zone / Belly Fairingz+CLG Bay / 3xCM- 300/WANKEL ENGINES Non-Pressurized Zone / Belly Fairingz+CLG Bay / APU P&W Non-Pressurized Zone / External / FUS (Hi-RAT) Non-Pressurized Zone / External / Wing (Hi-RAT) Non-Pressurized Zone / Internal / Hi-RAT Simple shared coffin (Diesel Eng.) Independent coffin (Diesel Eng.) Simple shared coffin (APU) B2b - Intallation / Coffin Configuration Independent coffin (APU) External Installation (Hi-RAT) External One unique tube A4 - Exhaust External Several tubes External Air Supply (Diesel Eng.) Cabin Air supply (Diesel Eng.) B5a - Air Supply (Only Diesel Eng. & APU) External Air Supply (APU) Cabin Air supply (APU) Single intake (Diesel Eng.) Multiple intake (Diesel Eng.) B5b - MPU Compartment Ventilation / Intake (Only Single intake (APU) Diesel Eng. & APU) Multiple intake (APU) Only Ventilation / Actuated ramps Only Ventilation / Non actuated ramps B5c - MPU Compartment Ventilation / Ramps (Only Diesel Eng. & APU) Only Ventilation + Cooling / Actuated ramps Only Ventilation + Cooling / Non actuated ramps Ejectors (Diesel Eng.) B6a - Ventillation on Ventilators (Diesel Eng.) ground / Diesel Engine External source (Diesel Eng.) Ejectors (APU) B6b - Ventillation on Ventilators (APU) ground / APU External source (APU) MPU heat exchanger within the coffin - Ambient Air A7 - Cooling (Only Diesel MPU heat exchanger out of the coffin Eng. Heat Exchangers) MPU heat exchanger within the coffin - Cabin Air Shared with MPU A8 - Cooling electrical generator Dedicated MPU Supply A9a - Gear box / Supply Independet With regulation (variable multiplication) A9b - Gear box / Regulation Without regulation (fixed multiply) 115 VFG (Diesel Eng.) 270 VDC (Diesel Eng.) 115 CFG (Diesel Eng.) B11 - Generators 230 VFG (APU) 115 V (Hi-RAT) B6a B6b Ventilation on ground MPU Ventilation on ground APU Yes Alternative B B Yes Alternative A A - Indedenpednt of systems - Taxi operation - Simplicity - Done by Manufactured - Included in price - Considered external air as intake source - if ventilation is not used in TAXI, Solution B to be considered A4 Exhaust No Alternative B B - Ease of installation A8 Cooling Electrical No Alternative A A - Best choice using technical Generator aspects - If the oil is different, there are different peaks of temperature, contamination.-> Could be neccesary to review B solution A9a Gearbox Supplier No Alternative A A A9b Gearbox Regulation No Alternative B B B1 Fuel architecture No Alternative A A - Maintainance B2b Enclosure No Alternative B B - Safety B5a Air Supply (for Diesel) No Alternative B B B5a Air Supply (for APU) No Alternative C C - In service operation C (115 KVA) -Self-contained B11 Generators Yes Alternative C APU A330 - Experienced in 115 RED SAFRAN - Experienced with suppliers TO Decision Table Consider A solution in case of 4 engines (2 coffins of 2 engines) Incompatibility Matrix Key Trade-off contributing to the requirement & Chosen solution ID Requirement Status Rq Target Req Type B0 - Mission Power Gen Selection B1 - Fuel Architecture / Integration (APU & Diesel Eng.) B2a - Intallation / Position B2b - Intallation / Coffin Configuration A4 - Exhaust B5a - Air Supply (Only Diesel Eng. & APU) B5b - MPU Compartment Ventilation / Intake (Only Diesel Eng. & APU) B5c - MPU Compartment Ventilation / Ramps (Only Diesel Eng. & APU) B6a - Ventillation on ground B6b A7 - Cooling (Only Diesel Eng. Heat Exchangers) A8 - Cooling electrical generator A9a - Gear box / Supply A9b - Gear box / Regulation B11 - Generators Are the chosen solution compliant with the rqt? TLARD Nominal Electrical Power 350kW@270VDC 3 kw@230vdc 50kW@28 VDC x x x YES TLARD Electrical Power with Single Failure 260kW@270VDC 40kW@28 VDC MPU generator failure x x x YES TLARD Civil Certification with EASA. CS 25 Certification Bases not existing for reciprocating engines APU x x x x x x x x x x x x x x x YES TLARD Mission System powered ON at altitudes from 7km to 12km above MSL only ft 20000ft up to x x YES TLARD Each Power Generator Unit shall be suitable for use on the ground and in flight 50 Kw ISA +40 To need to clarify the meaning of operation on ground x x YES Average internal noise level with Mission TLARD Systems in OFF at all speeds (power <80 db x x x x YES generation is included in Mission Systems) Controls for Power Generator Unit starting, It is assumed that EASA will shutdown, fire detection and fire require Safety related TLARD extinguishing (if required) shall be controls and indicating in x x x x x x x x x x x x x x YES Configuration provided in the cockpit/cabin. Check cockpit Sheet 9
10 SBCE- The Results Foster innovation Better master cost and Schedule Global optimum Adaptable to requirement evolutions Organize the fuzzy front-end part of a complex project Capitalize knowledge for future project Increase Learning 10
11 SBCE - Lessons Learnt and VoC 11
12 Airbus Future Challenges 12
13 Thank you
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