innovation and training at aerosud by dr k van rijswijk
DESCRIPTION
Dr K Van Rijswijk’s (Head of Advanced Composites, Aerosud Innovation and Training Centre, South Africa) presentation at the SATN Annual Conference 2009. Theme: “Technological innovation at Universities in South Africa: towards industrial and socio-economic development”16 - 17 July 2009Cape Peninsula University of TechnologyBellville Campus.TRANSCRIPT
Enhancing people, improving technologyEnhancing people, improving technology
Innovation and Training at Innovation and Training at AerosudAerosud
Dr. K. van RijswijkDr. K. van Rijswijk
Monday, April 10, 2023
Materials Processes
Design
SATN Annual Conference 2009SATN Annual Conference 200916-17 July16-17 JulyCape Peninsula University of TechnologyCape Peninsula University of TechnologyBellville CampusBellville Campus
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OutlineOutline
• Introduction AerosudIntroduction Aerosud• Stability vs. ChangeStability vs. Change• Aerosud Innovation & Training CentreAerosud Innovation & Training Centre• Example of InnovationExample of Innovation• UoT student characterizationUoT student characterization• ConclusionsConclusions• Questions / discussionQuestions / discussion
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Introduction AerosudIntroduction Aerosud• Formed in 1990Formed in 1990• Strong Engineering Design Capability Strong Engineering Design Capability • Production => 750,000 Details/Assy’s per yearProduction => 750,000 Details/Assy’s per year• 600 Staff 600 Staff • 95% Export95% Export
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Introduction AerosudIntroduction Aerosud
• Aerosud Holdings:Aerosud Holdings:– Aerosud Aerospace Systems: Aerosud Aerospace Systems:
• Military UpgradesMilitary Upgrades
– Aerosud Aviation:Aerosud Aviation:• Design and Manufacture of Aircraft structures and interiorsDesign and Manufacture of Aircraft structures and interiors
– Aerosud Innovation and Training Centre:Aerosud Innovation and Training Centre:• R&D, HCDR&D, HCD
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Introduction AerosudIntroduction Aerosud
Build-to-Print
Subcontract Design &
Manufacture
Risk-sharing Partnership
Product Ownership
Product Ownership
??
Galleys
Mil. Upgrades
A400M
A350
787
Boeing
BAE Systems
Boeing
Airbus
Etc etc
“Innovate to prevent that contract is moved to a lower wage country”
“Innovate to maintain or increase market share”
“Innovate to become a more attractive partner in
challenging projects”
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Stability vs. ChangeStability vs. Change
Continuous quality is one of the most important aspects Continuous quality is one of the most important aspects of aeronautical engineering:of aeronautical engineering:– Rules and regulationsRules and regulations– Certified processes, materials and personnelCertified processes, materials and personnel– Records, paperwork and traceabilityRecords, paperwork and traceability– Testing and proof of complianceTesting and proof of compliance
EASA Part 21 POAAS/EN9100
Production requires a stable environment:
“Always the same”
Production requires a stable environment:
“Always the same”
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Stability vs. ChangeStability vs. Change
Innovation is an equally important aspect:Innovation is an equally important aspect:– New materialsNew materials– New manufacturing processesNew manufacturing processes– New designs and applicationNew designs and application– New management systemsNew management systems– New marketing methodsNew marketing methods– Knowing what the customer is going to want (trends) before he Knowing what the customer is going to want (trends) before he
places an order: Can you guys make…Yes we can!places an order: Can you guys make…Yes we can!– ……
Innovation requires a dynamic environment:
“Continuous change”
Innovation requires a dynamic environment:
“Continuous change”
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Stability vs. ChangeStability vs. Change
Production (Always the same) and Innovation Production (Always the same) and Innovation (Continuous change) must not contaminate each (Continuous change) must not contaminate each other:other:– Spontaneous innovation might threaten stable Spontaneous innovation might threaten stable
productionproduction– Focusing on stable production might push innovation Focusing on stable production might push innovation
asideaside
Specialization!... Specialization!... With communication and an overlapWith communication and an overlap
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Stability vs. ChangeStability vs. Change
Stability Change
Production Innovation
Proven technology New technology
Repeatability Feasibility
Communication
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Aerosud ITCAerosud ITC
Aerosud Innovation & Training Centre:Aerosud Innovation & Training Centre:Process DevelopmentProcess Development
– Advanced Composite TechnologyAdvanced Composite Technology– High-Speed MachiningHigh-Speed Machining
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Aerosud ITCAerosud ITC
Development of new material applications and Development of new material applications and manufacturing technologies:manufacturing technologies:
““Saving time, costs and weight.”Saving time, costs and weight.”
Developing applications to maximize the benefit of Developing applications to maximize the benefit of the above mentioned technologies.the above mentioned technologies.
Training people at the same time to implement Training people at the same time to implement new technologies in the workshops.new technologies in the workshops.
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Ingredients for InnovationIngredients for Innovation
• Broad knowledge baseBroad knowledge base
• Customers (for who…?)Customers (for who…?)
• A network of experts (co-operation)A network of experts (co-operation)
• FundingFunding
• InfrastructureInfrastructure
• Implementation strategyImplementation strategy
• Adventurous mind-setAdventurous mind-set
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Aerosud ITCAerosud ITCBroad knowledge baseBroad knowledge base
Materials Processes
Design
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Aerosud ITCAerosud ITCBroad knowledge baseBroad knowledge base
Materials Processes
Design
Testing
Supplier relation
Manufacturing equipment
Tool design
Assembly
Finishes
Design values
Comparative studies
Qualification
Customer relation
Design rules
Processing envelope
Parameters and variables
Transport and Storage
Legislation
IP
Costs
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Aerosud ITC Co-operationAerosud ITC Co-operation
US:
• Thermoplastic Composites
• Titanium Machining
CUT:
• Direct manufacture
TUT:
• Composites
• High-speed machining
CSIR:
• Composites
• High-speed machining
• Direct Manufacture
UJ:
• Composites
AMT Composites
• Material supplier
Epsilon engineering:
• Tooling manufacturer
LST:
• Composite manufacturer
ANDTc:
• NDT
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FundingFunding
• Direct funding from customerDirect funding from customer• Own investmentOwn investment• Government funding:Government funding:
– AMTSAMTS– Innovation FundInnovation Fund– Teta Training grantsTeta Training grants– EU fundingEU funding– TIATIA– ……
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Implementation StrategyImplementation Strategy
• Active marketing of companies to obtain Active marketing of companies to obtain contracts that involve the newly developed contracts that involve the newly developed technologiestechnologies
• Training facilitiesTraining facilities
• FundingFunding
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Example of InnovationExample of Innovation
Development of a composite sliding door for Development of a composite sliding door for aircraft interiors:aircraft interiors:
• Lightweight type of garage door (no Aluminium)Lightweight type of garage door (no Aluminium)• Fully flat/smooth surface when closedFully flat/smooth surface when closed• FSTH compatibleFSTH compatible• Able to withstand a 90-kg abuse load without popping Able to withstand a 90-kg abuse load without popping
out of the railsout of the rails• 280.000 cycles (open-close)280.000 cycles (open-close)
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Composite Sliding DoorComposite Sliding Door
Innovation does not have
to be “difficult”
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Composite Sliding DoorComposite Sliding Door
Material Selection:Material Selection:• Bending stiffness: Composite Sandwich panelBending stiffness: Composite Sandwich panel
• Fatigue resistance: Thermoplastic composite skinFatigue resistance: Thermoplastic composite skin
• Assembly: Bonding with epoxy adhesiveAssembly: Bonding with epoxy adhesive
• Front finish: Decorative laminateFront finish: Decorative laminate
• Back finish: Flexible clothBack finish: Flexible cloth
• Side finish: Plastic cappingSide finish: Plastic capping
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Composite Sliding DoorComposite Sliding Door
Mechanical testing:Mechanical testing:
““confidence tests”confidence tests”
75kg75kg75kg75kg
185kg!185kg!stiff
flexible
280.000 cycles
Cyclic testing at UoT
Static testing at ITC
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Composite Sliding DoorComposite Sliding Door
Three routing concepts:Three routing concepts:
1
2
3
Routing Routing composite composite panel up to panel up to
the skinthe skin
Multi-step routingMulti-step routingBonding Bonding individual individual slats onto slats onto
flexible skinflexible skin
1 - Time-consuming1 - Time-consuming
2 - Allignment 2 - Allignment difficult to obtaindifficult to obtain Selected method
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Composite Sliding DoorComposite Sliding Door
• Full scale cyclic testing at SABSFull scale cyclic testing at SABS““certification tests”certification tests”
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Composite Sliding DoorComposite Sliding Door
INNOVATION?INNOVATION?
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UoT Student report:UoT Student report:
• Execution of work: Execution of work: 80%80%
• Participation in innovation: Participation in innovation: 25%25%– No ideas, suggestion, thoughts, opinionsNo ideas, suggestion, thoughts, opinions– Not the proper communication skills to solve Not the proper communication skills to solve
multi-disciplinary problems:multi-disciplinary problems:• How to express yourself in a discussion?How to express yourself in a discussion?• English (grammar, terminology, formulation)English (grammar, terminology, formulation)• Report writing, summarizing, presentations Report writing, summarizing, presentations
Composite Sliding DoorComposite Sliding Door
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Communication !!!!!!!!Communication !!!!!!!!
Stability Change
Production Innovation
Proven technology New technology
Repeatability Feasibility
CommunicationCommunication
Materials Processes
Design
Testing
Supplier relation
Manufacturing equipment
Tool design
Assembly
Finishes
Design values
Comparative studies
Qualification
Customer relation
Design rules
Processing envelope
Parameters and variables
Transport and Storage
Legislation
IP
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Present:Present:
UoT students excel at UoT students excel at implementing implementing solutionssolutions,…but are not ,…but are not problem solversproblem solvers. .
……This does not mean that UoTs are not This does not mean that UoTs are not innovation centres, I think you are doing a innovation centres, I think you are doing a brilliant job!brilliant job!
University of Technology StudentsUniversity of Technology StudentsTechnician
level
Engineering level
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Future ambition:Future ambition:• In order to move up to the engineering level:In order to move up to the engineering level:
– Actively embed “problem solving” and “innovation” in Actively embed “problem solving” and “innovation” in the curriculumthe curriculum(knowing what football is does not make you (knowing what football is does not make you automatically a football player)automatically a football player)
– Improve communication skills Improve communication skills
Trap:Trap:• If UoT students move up to the engineering If UoT students move up to the engineering
level, who will become our technicians?level, who will become our technicians?
University of Technology StudentsUniversity of Technology Students
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ConclusionConclusion
Innovation:Innovation:• Is a skillIs a skill• Right guy in charge, not necessarily an expertRight guy in charge, not necessarily an expert• Essential for the survival of an industryEssential for the survival of an industry• Innovation and steady production must not contaminate Innovation and steady production must not contaminate
each other, each other, communicationcommunication is essential is essential• Network of experts is required, Network of experts is required, co-operationco-operation• UoT students can already successfully participate in an UoT students can already successfully participate in an
innovation process, but innovation process, but communication skillscommunication skills need to need to improve in order to become innovators / problem solvers.improve in order to become innovators / problem solvers.
• Is successfully done at UoTs, don’t publish too much too Is successfully done at UoTs, don’t publish too much too early.early.
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Questions?
Dr. K. van Rijswijk
Aerosud ITC
012-662 5336