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iMAPC Informe resumido

Project ID: 277927
Financiado con arreglo a: FP7-JTI
País: Germany

Periodic Report Summary 5 - IMAPC (Development and validation of an integrated methodology in order to establish adapted production concepts for efficient turbofan engines)

Project Context and Objectives:

The aerospace industry is currently 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.

Within this project a new and innovative methodology for efficient turbofan engine and engine components will be developed in order to establish adequate and optimised strategies of manufacturing with respective production concepts.

Project Results:

Reporting period 5 compromises just work package 6 (excl. work package 1 - project management):

Work package 6 contains the summary and documentation of the generic methodology model developed in work packages 2 through 5. This WP summarises the whole project results in comprehensive project documentation. Results from the different project phases and the main results from the validation phase were described and handed over to MTU Aero Engines as well as all relevant project files and tools.

Potential Impact:

In order to support the manufacture of new turbofan engines and engine components to fulfil future requirements, this project focuses on the development of a new integrated methodology as a tool to figure out ideal strategies of manufacturing and production concepts for the current and future market situation.

The integrated methodology focuses on the change from a current “reacting position” of the manufacture to an “acting position”. Presently the manufacture reacts to changes within his environment, for instance changes of production volumes, new product designs, new technologies, etc., with changes in his production concept through late increase/decrease of capacities and resources, non-ideal changing layout and product segmentation, delayed integration of new technologies, etc. The new methodology allows the manufacture to verify how future changes like higher/lower volumes, different design, quality issues, etc. will affect the current strategy of manufacturing as well as the production concept on the shop floor in advance (top down approach). Furthermore the methodology gives the manufacturer a solution of an adapted new manufacturing strategy as well as concrete specifications for an ideal production concept for example type of product segmentation, capacities issues, production organisation, etc. Additionally, the methodology also allows the reversible proceeding based on a “bottom up” approach. Changes in current processes at the shop floor level, different supplier concepts, etc. can be evaluated regarding impacts on the overall manufacturing strategy. The methodology will gather existing strategies and concepts on different levels within the organisation and from different point of views (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, general guidelines for manufacturing etc. Following the methodology will process the input data based on rules, algorithm and knowledge databases in order to suggest proper future strategies of manufacturing and operationalize the results as production concepts.

The methodology is based on following constraints:

Robust – Means that the methodology leads to results based on the current business framework in a stable way. There should not be major changes for the strategy of manufacturing or the production concepts if minor input information were modified.

Sustainable –The results for strategy of manufacturing and production concepts must be sustainable and future-proof, because the manufacture will establish the way of production for new engines and components on the results of the methodology.

Systematic und repeatable–The methodology is based on a systematic proceeding structured by different levels of detail following a top-down and bottom-up approach. The methodology, based on rules and algorithm, can be operated repeatable 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 software tools the methodology can be applied in an efficient, simple and transparent way. In summary, the methodology enables the manufacture of new turbofan engines and components to get in position 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)

Expected impact:

The new development of efficient turbofan engines also has to include the research on new appropriated manufacturing strategies and production concepts on the shop floor. Due to the complex and integrated environment, characterised by fast changing constraints, such as volumes, product design, product spectrum, quality issues, etc., the manufacture needs a methodology and a supporting IT tool in order to find continuously the optimal production structure and alignment based on its main targets. Currently, there is no integrated approach to solve these challenges within the aerospace industry.

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. Through the aspect of an efficient way of production the project contributes to efficient turbofan engines through a reduced total energy balance (energy footprint) including production and life-cycle energy consumption. That leads further to a competitive advantage based on an energy point of view.

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
- Uses of modern technologies with short operating times
- Optimal workflow and process steps
- Appropriated staffing
- Modern logistics systems, 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.

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