aerospace & defense manufacturing · pdf fileof data from product design 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

2017.10.24 Siemens PLM Software

Agenda

Our vision for aerospace & defense

The digital twin - innovation

The digital thread - Sonaca



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



Agenda






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



Plan Your Future Factory

3Dprint a composite winglet

DESIGN

BUILD

Winglet manufacturing

Wing sub-assembly

Composites Inspection

Wing assembly

Wing paint

Assembly docs creation



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.




Inspect the composite parts for deficiencies

DESIGN

BUILD


Wing sub-assembly


Wing assembly

Wing paint




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.




Attach the wings to the fuselage

DESIGN

BUILD


Wing sub-assembly


Wing assembly

Wing paint




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




Paint the airplane

DESIGN

BUILD


Wing sub-assembly


Wing assembly

Wing paint




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.



Agenda




© SONACA 2017. This document is the property of and is Unrestricted.

Manufacturing Engineering PLM Project

PLM Connection 2017October 24th

© SONACA 2017. This document is the property of SONACA ; no part of it shall be reproduced or transmitted without the express prior written authorization of SONACA and its contents shall not be disclosed

Agenda

• Company introduction• Teamcenter EcoPLM project• Teamcenter Manufacturing implementation• Training & User adoption• End-to-End Business solution

16


COMPANY INTRODUCTION


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


• Assembly

• Machining

• Sheet forming

• Composite

• Processing

• Distribution

• Manpower : 1750


• 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

19


SONACA Group is active in five business lines

20

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

21


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)

1

• Cultural change• Supply chain optimization• Operational excellence

2

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)

4

5

6

©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


TEAMCENTER ECOPLM PROJECT

Project timeline

25

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


TEAMCENTERMANUFACTURINGIMPLEMENTATION


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

28


Head of Structure, Basic BOM ViewsEngineeringManufacturing

29


Manufacturing Definition Dossier (MDD)Basic Item View

30


Manufacturing Scenario (1)

32

Search from Customer P/N

A day in a life of a manufacturing engineer



33

Select engineering structure



34

Find the configuration node



35

Open the configured structure



36

Compare two engineering configurations



37

Select the same Part in each configuration



38

Graphical compare



39

Graphical compare



40

Graphical compare



41

Select the eBOM and the corresponding mBOM



42

Compare eBOM with mBOM



43

Find the Manufacturing Dossier (MDD) of the

assembly



44

Select the Tooling Definition Dossier (TDD)



45

View the Tooling Definition Dossier (TDD)



46

Direct view of the tooling specification



47

Select the tooling structure



48

View the tooling structure


TRAINING &USER ADOPTION


Training & User adoption

50

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


Training & User adoption

51

Adoption monitoring


END TO END

BUSINESS SOLUTION


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 !


Product Development

Master Data Business Data

Product Management Project Management

Product Management Project ManagementData Management

End to End Business Solutionfor Product (& Process) Development & Modification

http://int.sonaca.com/ws/projects/S1/projets-excellence/Development Process Mapping/DPM - Description overview.aspx


http://int.sonaca.com/sites/Business/SonMasterData/Pages/default.aspx



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



http://int.sonaca.com/sites/Business/DevelopmentPlanning/Pages/default.aspx

http://int.sonaca.com/sites/Business/DevelopmentPlanning/Pages/default.aspx



http://int.sonaca.com/business/programs/Design/Forms/By Type.aspx

http://int.sonaca.com/business/programs/Design/Forms/By Type.aspx

http://int.sonaca.com/ws/ged/s1/BSI/TM/Forms/AllItems.aspx

http://int.sonaca.com/ws/ged/s1/BSI/TM/Forms/AllItems.aspx


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


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)


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


CONCLUSIONS


SONACA DIGITAL ROADMAP

67

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…


SONACA MANUFACTURING DIGITAL ROADMAP

68


Engineering Services

69

SONACA Engineering Services

EngineeringServices

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