Final Report Summary - IMAPC (Development and validation of an integrated methodology in order to establish adapted production concepts for efficient turbofan engines)
Executive Summary:
In order to support the production of new turbofan engines and engine components meeting future challenges and requirements, the project “iMAPC” focuses on the development of a novel integrated methodology, which acts as a tool to develop strategies of manufacturing and production concepts for current and future market situations.
The integrated methodology focuses on the change from a current “reacting position” of manufacturing to an “acting position”. Presently, manufacturing reacts to changes within its environment, such as changes in production volumes, new product designs, new technologies, etc., with changes in its production concept by late increase or decrease of capacities and resources, respectively, non-ideal layout changes and product segmentation and delayed integration of new technologies. The new methodology allows manufacturing to investigate and verify how future changes such as higher or lower volumes, new designs and quality issues affect its current strategy as well as the production concept on the shop floor in advance (top down approach). Furthermore, the methodology provides manufacturing with an adapted manufacturing strategy as well as specifications necessary for suitable production concepts such as the required type of product segmentation, capacities issues and production organisation. Additionally, the methodology also allows reverse proceeding based on a “bottom up” approach. Hence, changes in current processes at the shop floor level, different supplier concepts, etc. can be evaluated with regard to their impacts on the overall manufacturing strategy.
The methodology will gather existing strategies and concepts on different levels within the organisation and from different points of view (e.g. product point of view, technology development point of view, management point of view) as well as relevant input parameters such as volumes, product spectrum and general guidelines for manufacturing. Subsequently, the methodology will process the input data based on rules, knowledge databases and a defined algorithm, in order to formulate suitable future strategies of manufacturing and operationalize the according results as production concepts.
The methodology is based on following constraints:
Robust – The methodology leads to results based on the current business framework in a stable way. Analogue to a control engineering system, this requires that no major changes for the strategy of manufacturing or the production concepts occur if minor input data is modified.
Sustainable – The results for the manufacturing strategy and the production concepts must be sustainable and future-proof, as MTU Aero Engines will define its production strategy for new aircraft engines and engine components based on the results of the methodology.
Systematic und repeatable – The methodology is based on a systematic proceeding structured into different levels of detail, following both top-down and bottom-up approach. The methodology, based on rules and algorithm, can be operated repeatedly in order to validate changing input parameters affecting the strategy of manufacturing and the resulting production concepts.
Applicable in an efficient way – Based on supporting tools, the methodology can be applied in an efficient, simple and transparent way.
In summary, the methodology enables manufacture of new turbofan engines and components to get in a position of being in the forefront of upcoming major changes affecting its strategy of manufacturing and its production concepts (top-down approach) and vice versa (bottom-up approach).
Project Context and Objectives:
The aerospace industry is faced with the development of new efficient turbofan engines, focused on fuel burn reduction combined with an additional decrease in noise emission. The upcoming engine programs and their components require new approaches regarding product materials, product design, engineering as well as challenging demands on supplier und supply chain processes. Based on the development of these new efficient turbofan engines, also the manufacturing process of the new programs has also to be considered within the integrated clean sky approach.
The major changes of the new products and product structures require that the high level strategy of manufacturing new turbofan engines and components has to be reviewed as well as the specific production concept on the shop floor. The production has to fulfil the future requirements of handling alternative materials, integrating new production technologies, shortening product life-time cycles, achieving target costs of manufacturing and decreasing lead times as well as increasing quality demands. Additionally, the production is encountered within a dynamic and volatile environment with fasten changing constrains and parameters regarding production volumes, product design changes and new technology processes. Finally the production of new efficient engines and engine parts has to be efficient itself in order to ensure an optimal total efficiency balance.
Currently, engines and parts manufactures are mainly based on widespread manufacturing strategies and conventional production concepts. They are often focused only on specific customer needs or product requirements rather to develop a comprehensive manufacturing strategy. The production concepts within a company are not necessarily integrated and aligned for future challenges. In addition, there are competing concepts and targets within a company focused on different point of views, such as product view, processes view, department and management aims. Therefore, the manufactures run the risk of losing productivity, sustainability and competitiveness in the future. Due to an increasing complex environment within different production sites, varying production technologies and the increasing challenges of new engines products the manufacture has to focus on a systematically methodology to design and develop ideal, integrated and sustainable manufacturing strategies and production concepts in order to ensure future product requirements and competitive capability. Compared to other industries such methodologies are already usual in some areas, e.g. within the planning of distribution centers or within aircraft catering facilities.
The main objectives of the project are:
- Investigate general research of methodologies in the field of manufacturing strategies and production concepts, evaluation of different methodology approaches and detailed specification of an appropriate solution model for MTU Aero Engines.
- Establish detailed understanding of the current situation regarding existing and planned manufacturing strategies and production concepts; understanding for concepts and targets at different hierarchical organisation levels and for different aims and concepts based on different views such as product view, plant view, technology issues, etc.
- Development of a generic methodology model with considering the specific aerospace requirements and manufacturing aspects.
- Establish supporting tools on a prototype status and/or functional specifications for applications in order to support the developed methodology.
- Main requirements to the methodology and tools are the attributes robust, sustainable, systematic/repeatable and efficient.
- Validate the methodology on a specific case study.
- Practical application of the methodology in a real environment
- All project information, data, decisions and main results including the outcomes of the validation phase has to be summarized within comprehensive project documentation.
Project Results:
The focus of the project was to develop an approach for an integrated methodology in order to establish adapted production concepts and respectively a production strategy for an aircraft engine manufacturer. The objective of the approach is to integrate current papers about production strategies, existing relevant methods, challenges of the future and requirements of an aircraft engine manufacturer.
Therefore it was necessary to get basic information about production strategies, to define the term and to classify the production strategy in the field of business strategies. Furthermore a detailed reflection of contents of a product strategy had to be researched. The next step was to summarise different methods to develop strategies, concepts and products, in order to get a basic overview of possibilities to define an approach. Additionally several production systems were investigated to find transferable parts to develop the methodology. Afterwards it was needed to carry out a detailed evaluation of the relevant methods with the help of an agreed rating system with different evaluation criteria in order to find the best fitting methodologies. Parts of them together with considering the challenges of the future and the requirements of an aircraft engine manufacturer were used to build up an own methodology approach. This had to be done, because no suitable methodology approach was found. This approach contains a descriptive model, which is build up of different indenture levels. These levels range from the strategic alignment of the production to different subareas that have to be defined in order to design the production strategy. Specifying each subarea requires different methods and input data, which have to be standardised.
Then it was necessary to create a comprehensive overview about the current work on manufacturing topics with direct or indirect impacts on future strategies and production concepts. Specified in the overview, all coherences and key influence factors on production concepts were identified and delivered. In addition, a weak point analysis and optimisation potentials are provided.
The core of the entire project is a generic methodology model in order to develop production strategies considering the specific requirements and manufacturing aspects within the aerospace industry (e.g. high quality requirements). In addition, supporting tools were developed which help to improve the repeatability and efficiency of the methodology. The developed methodology is structured in three levels. The main level is the concept level. Within this level the basis for a production strategy can be developed as well as the framework for implementation projects can be prepared. The concept level is structured in categories (e.g. location, product, technology), which have to be analysed. Necessary input data (e.g. market data) were defined and a structure was developed to analyse these categories. In addition a standarized process was defined to analyse the input data and develop concrete recommendations. A solution to consider possible coherences between the elements was implemented. In order to design a production strategy a methodology was developed which enables the user to formulate systematically a production strategy based on the analysis made on the concept level (bottom-up approach). In addition, the analysis and output data of the concept level represents the basis for implementation projects in order to bring the production strategy on the shop floor (top-down approach). During the development process each element was validated to ensure an accurate working of the logic of the methodologies and the supporting tools.
After the methodology model was developed, it was necessary to apply it in a real environment. Furthermore the application helped to find weaknesses in order to eliminate them, improved and standardized the methodology. In addition, the application of the methodology established optimal strategies and production concepts for the chosen objects. The methodology and the corresponding sub elements were adopted to the following product and technology groups: Titanium Blade Integrated Disks (Ti-Blisk), Nickel Blade Integrated Disks (Ni-Blisk), Joint Blade Integrated Disks, Disks, Sealing Rings, Spools, Blades & Vanes (High Pressure Turbine and Low Pressure Turbine), Casings, Guide Vanes (Outlet Guide Vanes and Inlet Guide Vanes), Assembling, Generative Manufacturing Technologies, Joining Technologies, Cutting Technologies, Inspection Technologies.
Potential Impact:
With this project a first comprehensive model will be achieved in order to find ideal manufacturing strategies and production concepts within the aerospace engine business. Having this model and an integrated methodology means a significant competitive advantage to the manufactures of engines and engine components within Europe. Due to the possibility of fast reacting to changing constraints the manufacture always gains ideal production concepts and technologies in order to meet or undercut competitive manufacturing costs. That leads further to a competitive advantage based on an energy point of view.
In the following some impact aspects are described in detail. Therefore, the impact aspects are distinguished in cost impact, technical impact, efficiency impact, transferability and further proceedings.
1. Cost impact
The methodology will provide the manufacture with optimal manufacture strategies and production concept based on the input data and the main targets. An optimal manufacturing strategy and production concept determines for example:
- Shorten throughput time
- Reduced stock value
- Use of modern technologies with short operating times
- Optimal workflow and process steps
- Appropriated staffing, etc.
Considering the aspects of optimal manufacturing strategy and production concept it leads to lower overall manufacturing cost and therefore to competitive total cost of engines and components. The risk to use improper concepts based on the actual market situation and generating not competitive costs for parts will be reduced significantly. The methodology makes a considerable contribution to the cost competitive advantage of European aircraft engines and engine parts.
2. Technical impact
The work within the project will concentrate on manufacturing strategies and production concepts beyond the state of art in a technical point of view. Through the integrated approach long term issues such as new technology processes, upcoming production control systems, etc. will be gathered and implemented in a comprehensive way. The overall approach avoids the current problems to introduce for instance new technologies before implementing e.g. organisational structures. Through the methodology approach all relevant constraints as well as the coherence between changes will be validated and consolidated to a powerful manufacturing strategy and a concrete production concept. Both will be characterized through a meaningful integration of newest technology and processes beyond the state of art in an appropriate timing perspective. The methodology developed within this project will ensure the integrated use of latest technology as a major competitive advantage against Non-European manufactures.
3. Efficiency impact
The methodology concentrates on the outcome of efficient manufacturing strategies and production concepts. The main focus of the production of efficient new engine programs is also the efficient way of manufacturing complete engines and engine components. Therefore an integral part of the model is to achieve efficient production systems in strategical way as well as on shop floor level. Based on strategical outcomes of the methodology an efficient production can be achieved for instance by reducing transport cost within a production network with different manufacturing plants, decisions for alternative high level technology processes, etc. On a shop floor level efficient production can be implemented through concepts with low energy consumption, reduction of raw materials and utilities, avoiding wastage during the workflow and use of energy-saving manufacturing technologies.
4. Transferability
After the development of the methodology for the aircraft manufacturing industry the further transferability to other European industries can be forced. With the transfer to other industries also competitive advantages can be achieved. Therefore the methodology strengthens the competitive position of European industry within a world market and leads finally to a contribution to safeguard employment within Europe.
5. Further Proceeding
In order to bring about the described impacts the prototype tools has to be developed to a series-production readiness. Therefore detailed functional specification for the software development including the algorithm, database structure, etc. has to be created. After the final development of the software application the methodology has to be used within the Clean Sky demonstrator and other MTU Aero Engines manufacturing areas as in the validation phase. During the use of the software tool additional adjustments as well as expansion of the knowledge-base are necessary.
In order to support the production of new turbofan engines and engine components meeting future challenges and requirements, the project “iMAPC” focuses on the development of a novel integrated methodology, which acts as a tool to develop strategies of manufacturing and production concepts for current and future market situations.
The integrated methodology focuses on the change from a current “reacting position” of manufacturing to an “acting position”. Presently, manufacturing reacts to changes within its environment, such as changes in production volumes, new product designs, new technologies, etc., with changes in its production concept by late increase or decrease of capacities and resources, respectively, non-ideal layout changes and product segmentation and delayed integration of new technologies. The new methodology allows manufacturing to investigate and verify how future changes such as higher or lower volumes, new designs and quality issues affect its current strategy as well as the production concept on the shop floor in advance (top down approach). Furthermore, the methodology provides manufacturing with an adapted manufacturing strategy as well as specifications necessary for suitable production concepts such as the required type of product segmentation, capacities issues and production organisation. Additionally, the methodology also allows reverse proceeding based on a “bottom up” approach. Hence, changes in current processes at the shop floor level, different supplier concepts, etc. can be evaluated with regard to their impacts on the overall manufacturing strategy.
The methodology will gather existing strategies and concepts on different levels within the organisation and from different points of view (e.g. product point of view, technology development point of view, management point of view) as well as relevant input parameters such as volumes, product spectrum and general guidelines for manufacturing. Subsequently, the methodology will process the input data based on rules, knowledge databases and a defined algorithm, in order to formulate suitable future strategies of manufacturing and operationalize the according results as production concepts.
The methodology is based on following constraints:
Robust – The methodology leads to results based on the current business framework in a stable way. Analogue to a control engineering system, this requires that no major changes for the strategy of manufacturing or the production concepts occur if minor input data is modified.
Sustainable – The results for the manufacturing strategy and the production concepts must be sustainable and future-proof, as MTU Aero Engines will define its production strategy for new aircraft engines and engine components based on the results of the methodology.
Systematic und repeatable – The methodology is based on a systematic proceeding structured into different levels of detail, following both top-down and bottom-up approach. The methodology, based on rules and algorithm, can be operated repeatedly in order to validate changing input parameters affecting the strategy of manufacturing and the resulting production concepts.
Applicable in an efficient way – Based on supporting tools, the methodology can be applied in an efficient, simple and transparent way.
In summary, the methodology enables manufacture of new turbofan engines and components to get in a position of being in the forefront of upcoming major changes affecting its strategy of manufacturing and its production concepts (top-down approach) and vice versa (bottom-up approach).
Project Context and Objectives:
The aerospace industry is faced with the development of new efficient turbofan engines, focused on fuel burn reduction combined with an additional decrease in noise emission. The upcoming engine programs and their components require new approaches regarding product materials, product design, engineering as well as challenging demands on supplier und supply chain processes. Based on the development of these new efficient turbofan engines, also the manufacturing process of the new programs has also to be considered within the integrated clean sky approach.
The major changes of the new products and product structures require that the high level strategy of manufacturing new turbofan engines and components has to be reviewed as well as the specific production concept on the shop floor. The production has to fulfil the future requirements of handling alternative materials, integrating new production technologies, shortening product life-time cycles, achieving target costs of manufacturing and decreasing lead times as well as increasing quality demands. Additionally, the production is encountered within a dynamic and volatile environment with fasten changing constrains and parameters regarding production volumes, product design changes and new technology processes. Finally the production of new efficient engines and engine parts has to be efficient itself in order to ensure an optimal total efficiency balance.
Currently, engines and parts manufactures are mainly based on widespread manufacturing strategies and conventional production concepts. They are often focused only on specific customer needs or product requirements rather to develop a comprehensive manufacturing strategy. The production concepts within a company are not necessarily integrated and aligned for future challenges. In addition, there are competing concepts and targets within a company focused on different point of views, such as product view, processes view, department and management aims. Therefore, the manufactures run the risk of losing productivity, sustainability and competitiveness in the future. Due to an increasing complex environment within different production sites, varying production technologies and the increasing challenges of new engines products the manufacture has to focus on a systematically methodology to design and develop ideal, integrated and sustainable manufacturing strategies and production concepts in order to ensure future product requirements and competitive capability. Compared to other industries such methodologies are already usual in some areas, e.g. within the planning of distribution centers or within aircraft catering facilities.
The main objectives of the project are:
- Investigate general research of methodologies in the field of manufacturing strategies and production concepts, evaluation of different methodology approaches and detailed specification of an appropriate solution model for MTU Aero Engines.
- Establish detailed understanding of the current situation regarding existing and planned manufacturing strategies and production concepts; understanding for concepts and targets at different hierarchical organisation levels and for different aims and concepts based on different views such as product view, plant view, technology issues, etc.
- Development of a generic methodology model with considering the specific aerospace requirements and manufacturing aspects.
- Establish supporting tools on a prototype status and/or functional specifications for applications in order to support the developed methodology.
- Main requirements to the methodology and tools are the attributes robust, sustainable, systematic/repeatable and efficient.
- Validate the methodology on a specific case study.
- Practical application of the methodology in a real environment
- All project information, data, decisions and main results including the outcomes of the validation phase has to be summarized within comprehensive project documentation.
Project Results:
The focus of the project was to develop an approach for an integrated methodology in order to establish adapted production concepts and respectively a production strategy for an aircraft engine manufacturer. The objective of the approach is to integrate current papers about production strategies, existing relevant methods, challenges of the future and requirements of an aircraft engine manufacturer.
Therefore it was necessary to get basic information about production strategies, to define the term and to classify the production strategy in the field of business strategies. Furthermore a detailed reflection of contents of a product strategy had to be researched. The next step was to summarise different methods to develop strategies, concepts and products, in order to get a basic overview of possibilities to define an approach. Additionally several production systems were investigated to find transferable parts to develop the methodology. Afterwards it was needed to carry out a detailed evaluation of the relevant methods with the help of an agreed rating system with different evaluation criteria in order to find the best fitting methodologies. Parts of them together with considering the challenges of the future and the requirements of an aircraft engine manufacturer were used to build up an own methodology approach. This had to be done, because no suitable methodology approach was found. This approach contains a descriptive model, which is build up of different indenture levels. These levels range from the strategic alignment of the production to different subareas that have to be defined in order to design the production strategy. Specifying each subarea requires different methods and input data, which have to be standardised.
Then it was necessary to create a comprehensive overview about the current work on manufacturing topics with direct or indirect impacts on future strategies and production concepts. Specified in the overview, all coherences and key influence factors on production concepts were identified and delivered. In addition, a weak point analysis and optimisation potentials are provided.
The core of the entire project is a generic methodology model in order to develop production strategies considering the specific requirements and manufacturing aspects within the aerospace industry (e.g. high quality requirements). In addition, supporting tools were developed which help to improve the repeatability and efficiency of the methodology. The developed methodology is structured in three levels. The main level is the concept level. Within this level the basis for a production strategy can be developed as well as the framework for implementation projects can be prepared. The concept level is structured in categories (e.g. location, product, technology), which have to be analysed. Necessary input data (e.g. market data) were defined and a structure was developed to analyse these categories. In addition a standarized process was defined to analyse the input data and develop concrete recommendations. A solution to consider possible coherences between the elements was implemented. In order to design a production strategy a methodology was developed which enables the user to formulate systematically a production strategy based on the analysis made on the concept level (bottom-up approach). In addition, the analysis and output data of the concept level represents the basis for implementation projects in order to bring the production strategy on the shop floor (top-down approach). During the development process each element was validated to ensure an accurate working of the logic of the methodologies and the supporting tools.
After the methodology model was developed, it was necessary to apply it in a real environment. Furthermore the application helped to find weaknesses in order to eliminate them, improved and standardized the methodology. In addition, the application of the methodology established optimal strategies and production concepts for the chosen objects. The methodology and the corresponding sub elements were adopted to the following product and technology groups: Titanium Blade Integrated Disks (Ti-Blisk), Nickel Blade Integrated Disks (Ni-Blisk), Joint Blade Integrated Disks, Disks, Sealing Rings, Spools, Blades & Vanes (High Pressure Turbine and Low Pressure Turbine), Casings, Guide Vanes (Outlet Guide Vanes and Inlet Guide Vanes), Assembling, Generative Manufacturing Technologies, Joining Technologies, Cutting Technologies, Inspection Technologies.
Potential Impact:
With this project a first comprehensive model will be achieved in order to find ideal manufacturing strategies and production concepts within the aerospace engine business. Having this model and an integrated methodology means a significant competitive advantage to the manufactures of engines and engine components within Europe. Due to the possibility of fast reacting to changing constraints the manufacture always gains ideal production concepts and technologies in order to meet or undercut competitive manufacturing costs. That leads further to a competitive advantage based on an energy point of view.
In the following some impact aspects are described in detail. Therefore, the impact aspects are distinguished in cost impact, technical impact, efficiency impact, transferability and further proceedings.
1. Cost impact
The methodology will provide the manufacture with optimal manufacture strategies and production concept based on the input data and the main targets. An optimal manufacturing strategy and production concept determines for example:
- Shorten throughput time
- Reduced stock value
- Use of modern technologies with short operating times
- Optimal workflow and process steps
- Appropriated staffing, etc.
Considering the aspects of optimal manufacturing strategy and production concept it leads to lower overall manufacturing cost and therefore to competitive total cost of engines and components. The risk to use improper concepts based on the actual market situation and generating not competitive costs for parts will be reduced significantly. The methodology makes a considerable contribution to the cost competitive advantage of European aircraft engines and engine parts.
2. Technical impact
The work within the project will concentrate on manufacturing strategies and production concepts beyond the state of art in a technical point of view. Through the integrated approach long term issues such as new technology processes, upcoming production control systems, etc. will be gathered and implemented in a comprehensive way. The overall approach avoids the current problems to introduce for instance new technologies before implementing e.g. organisational structures. Through the methodology approach all relevant constraints as well as the coherence between changes will be validated and consolidated to a powerful manufacturing strategy and a concrete production concept. Both will be characterized through a meaningful integration of newest technology and processes beyond the state of art in an appropriate timing perspective. The methodology developed within this project will ensure the integrated use of latest technology as a major competitive advantage against Non-European manufactures.
3. Efficiency impact
The methodology concentrates on the outcome of efficient manufacturing strategies and production concepts. The main focus of the production of efficient new engine programs is also the efficient way of manufacturing complete engines and engine components. Therefore an integral part of the model is to achieve efficient production systems in strategical way as well as on shop floor level. Based on strategical outcomes of the methodology an efficient production can be achieved for instance by reducing transport cost within a production network with different manufacturing plants, decisions for alternative high level technology processes, etc. On a shop floor level efficient production can be implemented through concepts with low energy consumption, reduction of raw materials and utilities, avoiding wastage during the workflow and use of energy-saving manufacturing technologies.
4. Transferability
After the development of the methodology for the aircraft manufacturing industry the further transferability to other European industries can be forced. With the transfer to other industries also competitive advantages can be achieved. Therefore the methodology strengthens the competitive position of European industry within a world market and leads finally to a contribution to safeguard employment within Europe.
5. Further Proceeding
In order to bring about the described impacts the prototype tools has to be developed to a series-production readiness. Therefore detailed functional specification for the software development including the algorithm, database structure, etc. has to be created. After the final development of the software application the methodology has to be used within the Clean Sky demonstrator and other MTU Aero Engines manufacturing areas as in the validation phase. During the use of the software tool additional adjustments as well as expansion of the knowledge-base are necessary.