a new approach to weight management
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A new approach to Weight Management
Luisa Rovera ICT - Simulation Data Management, CAE & CFD
2013 Altair Technology Conference
Turin, April 24th 2013
ABSTRACT
A proper Weight & Balance management is a must for AgustaWestland, as it can identify areas where it is possible to save empty weight to improve helicopter pay load capacity and it can trace potential weight increments that might lead to customers’ claims.
In terms of technology, two main applications were delivered to foster AW Weight & Balance management process:
Weight Assistant: to extract advanced weight information from CAD environment.
Weight Analytics: to empower the Engineers and Executives to make better and faster decisions by managing the entire Weight & Balance process
Weight Assistant, an integrated CATIA V5 application to promote AW methodologies standardization; this application performs a realistic weight prediction and guarantees repeatability over time and user independence, thanks to an unambiguous classification of weight calculation rules per components and Departments.
Furthermore, the automatic calculation of main aircraft consumables (sealant, paint ...) contribution has been implemented.
Weight Analytics, openly architected and highly configurable tool, allows to visualize, analyse and predict W&B at any point in time during the entire Product Life Cycle, and streamline time consuming repetitive tasks associated with data consolidation.
This application reduces the time requested to asses Weight & Balance and it improves both quality and robustness with integrated, transparent and standardized automation to consolidate data sources combined with best-in-class methods in Business Analytics.
The approach of Weight Analytics supplies a common and integrated environment for the management and monitoring of the product weight since the very first phases of the product concept development: indeed Weight Analytics architecture is grounded on a functional view approach, a way to manage, coordinate and consolidate inputs to the design process coming from a number of stakeholders, both internal or suppliers.
Weight Analytics and the Product Life Cycle
“AgustaWestland Weight Analytics” (AWWA) supports W&B engineering all over the phases of product life cycle by managing and tracing BOMs and calculation with different product views:
• during Concept & Feasibility, W&B is supporting the General Design & Architecture functions with functional W&B studies at product level and system level, W&B data are modified without any change control;
• during Design & Development W&B engineering is managing both, the functional and the physical product structure, with change control;
• during Serial Program phase, W&B engineering is tracing the physical product structure, with change control.
Main Phases of the Weight & Balance Process
• The management of mass data will be based on "Target Setting" and "Target Monitor" logic, throughout all stages of development.
• Typically a new project starts identifying a product as a reference • From this reference we start to identify the content of the new product, according to its requirements by the
management of the "carry-over" parts and new specific parts.
Reference Baseline
Baseline Update
Mass Targets
Current Design of the New Prd
Struttura
Sistemi
Potenza
Comfort
Sicurezz
a
Finizioni
0 20 40 60 80 100
84.
3
18.
5
17.
5
8.7
23.
6
63.
6
27.4 27.4
38.6
34.6
46.945
Review1 Review2
Baseline Target Current
25
32
37
BL PR1 PR2
ECR/ECO
ECR/ECO
ECR/ECO
Sis 1
Sis 2
Sis 3
Sis 4
Sis 5
W&B
Reference
Target
Calculated Estimated
Weighed
Main Phases of the Weight & Balance Process
Weight evolution management:
prediction, calculation, reconciliation, weighting:
Continuous weight verification, amendment and alert considering:
– accurate target weight definition
– designed parts calculated weight verification
– calculated weight vs. target weight comparison
– actual weight vs. calculated weight reconciliation
– actual weight conformity
Weight Management in the lifecycle and
contractual requirements compliance, providing:
H/C Weight prediction
Helicopter weight aggregation
(Breakdown per P/N, per military codes, material )
Within the engineering process of a new product, the current status
of development is measured both against the baseline weight and
the target weight. The baseline weight changes along the
development every time a change occurs.
The engineering process of new parts articulates along several
revisions, trials and errors, which involve each single component of
the EBOM. AWWA keeps always track of such a changing
framework and returns the weight manager the exact current
position of the engineering process, detailed along all the EBOM
items.
For each item the weight manager can recognize the current
weight, the level of accuracy of the data CoG, inertias and the
history of revisions. That way he can always perform a detailed and
reliable review and analysis to plan how to move forward.
Weight Assistant: Calculation Engine into Catia V5
Based on the classification of the currently adopted weight calculation rules per
relevant Components of each Department, Weight Assistant is
an integrated CATIA V5 application developed to:
DEP
AR
TMEN
T :
AIR
FRA
ME
SYST
EM
COMPONENT CALCULATION
CATEGORY
Angular,
bracket METALLIC
Firewall
Grid
Cowling skin Composite
Seal MANUAL
INPUT Other (to be
spec.)
Promote AgustaWestland design methodologies standardization
Guarantee repeatability over time and user independence
To predict the most accurate and realistic weight
during the product development phase, an easy
way to extract the contribution of main
consumables has been implemented.
Weight Assistant: Calculation Engine into Catia V5
Weight Analytics and Functional Views • The “view” is a representation of the product composition, where all the components are managed and grouped
into different hierarchical levels accordingly to aggregation rules.
• Each product can be represented according different logics and rules, corresponding to different typology of
structures.
• The functional structure is a unifying element between the different views of all the experts involved in the
development process, and frequently corresponds to the vision of the top management.
Engineering View
Typical View of designers and
technicians, defined accordingly functional
subsystems, tied to CAD tools and
reported in the PLM
Manufacturing View
Very flat View of the product, directly linked with the
workflow across the manufacturing lines and tooling units in
the plants.
OI6
r24
1990
OI7
r--
OI1
r24
OI5
r24
OI3
r24
OI4
r5
OI2
r10
OI8
r--
Dis 1 Dis 3
Dis 6 Dis 4
Dis 5
Dis 2 Dis 7 Dis 8
1
2
1
2
AWWA Functional
Views Functional
Views
Engineering
Manufacturing
SAWE Functional View example • The Society of Allied Weight Engineers is an international organization whose purpose is to promote the recognition of
Weight Engineering as a specialized branch of engineering. The Society is organized into 22 chapters with members from across the United States, Europe, United Kingdom, and Canada.
• The Society offers to members and industry a medium for the pooling and exchange of data and experience at local and regional levels, fostering a higher degree of efficiency in mass properties engineering topics.
The SAWE View
22
Page
1288 Row
4836 Column
PART NUMBER
ATA100 Functional View example
W&B Process and Analytics
• Quick, reliable and current update of product weight status.
• Powerful BA tools to analyze and compare BOM composition and attributes, to support decisions on how to move forward and minimize risk.
• Based on the functional-view approach, it offers a way to manage, coordinate and consolidate inputs to the design process coming from a number of stakeholders, both internal or suppliers.
• The Weight Analytics solution provides high data consistency and transparency, standardization and
automation of workflows, enhanced tools to support analysis and decision-making, leveraging best-in-class
methods from the Business Analytics world.
W&B Analytics Report Example
Advantages from the AWWA System
• Empowerment of qualified workforce
– AWWA relieves engineers from data retrieval recurrent tasks and bring them back to data analysis and design intensive activities, which return a significantly higher added value to process and product quality.
• User’s rights management
– AWWA allows to identify and track process and data owners, in order to easily clearify responsibilities and fairly deal with possible conflicts.
• User’s role management
– AWWA solution offer different views and accesses for different users, to be modeled according the company extended (e.g. including suppliers) organization structure. This is especially crucial where strict confidentiality rules apply by authorities’ or customers’ request.
• Enhanced prediction capacity and risk management
– AWWA offers managers the possibility to foresee the impact of changes occurring in the future, to perform what if analysis, and eventually cut the risk factors.
Advantages from the AWWA System
• Consistency and stability of information
– AWWA technology provides high data consistency and transparency, standardization and automation of workflows, across distributed data repositories and process owners.
• Standard and regular reporting
– AWWA enables a protocol of standard and regular reporting - targeted to different recipients across the company’s organization infrastructure.
• Advanced analytics
– AWWA provides sophisticated calculations, analysis and KPIs that are performed quickly automatically by the system.
• Interface between PLM, ERP and early design phases
– AWWA provides concept engineers and architects an effective toolkit to quickly and reliably manage early design phases and streamline the evaluation/feasibility studies that end to the detailed design stage.
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