aircraft oems’ requirements and harness manufacturers’ challenges - lessons learnt
TRANSCRIPT
Aircraft Cabling Conference, Hamburg, 2014 1
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Lessons Learned –Aircraft OEM’s Requirements and Harness Manufacturer’s Challenges
Advanced Aircraft Cabling Conference
Hamburg, July 8, 2014
Aircraft Cabling Conference, Hamburg, 2014 2
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Lessons Learned – Aircraft OEM’s Requirements and Harness Manufacturer’s Challenges
Contents Company Profile Aircraft OEM’s Requirements – Cabin Side Challenges Conclusions
Aircraft Cabling Conference, Hamburg, 2014 3
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Company ProfileCompetencies
Customized Harness Manufacturing for Aerospace & Defence for 30 years Focussing on small and medium series Customization, Quality, Service/OTD & Price/Performance Facilities in Bremerhaven, Bremen (both Germany) and Kanpur (India) app. 160 employees
Three major Branches Electrical Harnesses: Design – Manufacturing – Repair for AeroSpace & Defence Supply of temporary workers: Electrical Harness Design Engineers and Integration Staff Passenger Convenience Solutions: StarLight – Sensors – Controllers -
WasteWaterSystem
Aircraft Cabling Conference, Hamburg, 2014 4
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
OEM RequirementsSimplified View System
Harnesses within Cabin = Broad variety of different harnesses Shielding concept -> weight Supply Lines -> length/material -> weight Overhead Bins/Panels -> quantity -> weight Monuments
Galleys -> power Lavatories -> variety -> standardization Crew rest -> cabin within cabin/variety -> standardization
Seats F/Cl -> complexity/space (functionality, IFE) C/Cl -> quantity/complexity/space (functionality, IFE) Y/Cl -> quantity (IFE) -> standardization
Aircraft Cabling Conference, Hamburg, 2014 5
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
OEM RequirementsSimplified View Harness
Electrical Harness
Price
Electrical Properties
Weight
Mechanical Properties
Function
Standardization
Aircraft Cabling Conference, Hamburg, 2014 6
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Manufacturer‘s ChallengesCost, Cost, Cost?
Harness Manufacturing - Challenging Environment
Material Cost Last Minute Changes
Customization
On-time Delivery
Personnel Cost
Productivity
Logistics cost
Aircraft Cabling Conference, Hamburg, 2014 7
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Manufacturer‘s ChallengesHigh value details!
Assembled by hand631 parts100% precisionsells at….?
€ 160.000 in Gold – limited quantityEven a Rolex Daytona (only 290 parts) in steel sells at € 10.000 – high quantity
Aircraft Cabling Conference, Hamburg, 2014 8
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Manufacturer‘s ChallengesHigh value details?
assembled by hand753 parts100% precisionSells at…….?
Aircraft Cabling Conference, Hamburg, 2014 9
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Manufacturer‘s ChallengesDetails!
Cable type/ length Cable marking (each line individually laser marked) Sleeves (markings) Protection devices (sleeves, taping, slotted mesh…) Contacts (pin/socket) Connectors (broad variety…) Backshells (metallic, plastics, metalized plastics…) Binding technology (ty raps, knotting…) ….and assembly is mainly hand made…
Quality assurance is a challenging duty!
Aircraft Cabling Conference, Hamburg, 2014 10
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Feedbackto OEM
Initiate mass reduction optimized harnesses based on new materials screening material Decide earlyearly workshop establishment
Connect Design & BTP process Combine all tasks/processes avoid I/F problems optimize project management getting smarter & more cost efficient at an early stage
Reduce hurdles certification time interval Trigger (partly) automated manufacturinggetting smarter & more cost efficient at an early stage
Design with Love! (technology- and process-wise) …. Harness comes latest and it (often) looks that way
Aircraft Cabling Conference, Hamburg, 2014 11
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Feedbackto Supply Industry
Examples Laser printing, cutting + stripping, crimping one side Pin allocation support/semi-automation Fool-proof solutions (avoid retention test) Improve ergonomics: Female workers – small hands – large tools
Design for Automation Design Automation (printing, cutting, stripping, crimping machine) Improve tooling
Aircraft Cabling Conference, Hamburg, 2014 12
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
Lessons Learned – Aircraft OEM’s Requirements and Harness Manufacturer’s Challenges
Conclusion More standardization seems desirable Electrical harnesses are not receiving the “love” they deserve Hand made precision - little to no automation forever? Only the perfect product works:
On spec On cost On time
Aircraft Cabling Conference, Hamburg, 2014 13
E.I.S. ELECTRONICS GMBHAviation & Space Technology
30/06/2014
The End
Thank you for your attention!