25th Anniversary IDEKOIK4

Manufacturing technologies as a key enabler for increasing competitiveness in gas turbine manufacture
Alvaro Vacas Cortadi
25th Anniversary IDEKO IK4

Table of Contents

ITP The market & business Manufacturing technologies Working practices Conclusion

25th Anniversary IDEKO IK4

Table of Contents

ITP The market & business Manufacturing technologies Working practices Conclusion

25th Anniversary IDEKO IK4

ITP Industria de Turbo Propulsores S.A.

6 companies in the group, located in 6 countries, 18 workcenters 2.700 employees, ~2.000 in Spain, ~1.200 in Basque Country 482m sales in 2010

Capabilities
a

Internationalization
Global market Production in , $ & Low cost & high value added

Vertical integration
ITA ; pipes PCB; investment castings a
a

LPTs design and make Engines assembly & testing Engines maintenance

25th Anniversary IDEKO IK4

ITP Operations MAKE/BUY

ITP Zamudio

ITA

PCB

ITP Ajalvir

Competitiveness

Benchmark

Make

Buy

Protect

ITP UK

ITR

Criticality
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Table of Contents

ITP

The market & business

Manufacturing technologies Working practices Conclusion

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Aeronautical market commercial aviation

Raw material suppliers
Aircraft manufacturer (OEM Aircraft)
Engines

Aircrafts & engines

Tier 2 Tier 1 OEMs Suppliers Partnerts Engine

Spare engine parts

Airliner

Parts

Manufacturing Aircraft/Engine Services

Maintenance Centers

Maintenance 25th Anniversary IDEKO IK4

Globalization - Airlines

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Globalization - Aircrafts

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Globalization - Engines

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The situation of the industry global recovery

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Future products

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Environmental requirements
ACARE (*) 2020 and the environmental objectives (**): reduce fuel consumption and CO2 emissions by 50% per passenger kilometer reduce NOx emissions by 80% (associated to C02 emissions and combustion technology improvements) reduce perceived noise by 50% make substantial progress in reducing the environmental impact of the manufacture, maintenance and disposal of aircraft and related products ACARE has identified the main contributors to achieving the above targets. The predicted contributions to the 50% CO2 emissions reduction target are: Efficient aircraft: 20-25% Efficient engines: 15-20% (SFC improvement) Improved air traffic management: 5-10% * ACARE; Advisory Council for Aeronautical Research in Europe ** Compared to 2000

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New engine architectures

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Oil and material prices

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Exchange rates

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Buyer driven market

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Labour costs

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ANLISIS INTERNO Labour costs vs competitiveness

125%

Manuf. Cost (50% HH - 50% HM)

100% 90%

80%

70%

60% Espaa EEUU Mexico Polonia Brasil India China

Source: ICEX 2009 and ITPs estimates

Spain competitivines ranking has fallen from 29th to 33th from 2008-2009 period to 2009-2010. Source; World Economic Forum 25th Anniversary IDEKO IK4

Supply chain rationalization Reduction in the number of suppliers. Increase the risk & revenue partnership content. Increase the dollar content. Increase the Low Cost Countries content.
Rolls-Royce - Number of suppliers
450 400 350 300 250 200 150 100 50 0 RB211-524 (1977) Trent 700 ( 1995) Trent 900 ( 2004) Trent 1000 ( 2008) Trent XWB ( 2011)

Old RR engine ( 1995)

New RR engine ( 2001)

15% RRSP 175 suppliers 40% of costs in US$ 5% of cost is located at LCCs

45% RRSP 60 suppliers 64% of costs in US$ 20% of cost is located at LCCs

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ANLISIS INTERNO Low Cost Countries (LCC)

Mexico & China as major recipients of Aero investments

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Low Cost Countries Mexico sample

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Make vs buy Rolls Royce

MAKE efficiency, $ MAKE - Insourcing BUY - LCC Sourcing

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Make vs buy GeneralANLISIS INTERNO Electric

MAKE efficiency, $ MAKE - Insourcing BUY - LCC Sourcing

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Make vs buy ANLISIS INTERNO Snecma

MAKE efficiency, $ MAKE - Insourcing BUY - LCC Sourcing

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ANLISIS INTERNO Make vs buy MTU

MAKE efficiency, $ MAKE - Insourcing BUY - LCC Sourcing

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ANLISIS INTERNO Make vs buy Avio

MAKE efficiency, $ MAKE - Insourcing BUY - LCC Sourcing

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ANLISIS Make vs buy INTERNO ITP

MAKE efficiency, $ MAKE - Insourcing BUY - LCC Sourcing

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Market & Business Challenges

MARKET Global recovery Increased Volumes. Buyer driven market. Escalating Oil & metal prices. Dollar vs uro volatility. Labour costs increasing. Market globalization. LCCs industry development. Make vs Buy policies. Supply chain rationalization Novel engine & components architectures. Environmental objectives. Reduced time to market. New materials and processes. Reduced Unit Cost. Reduced Tooling Costs. BUSINESS Process capability & delivery adherence.

To remain competitive we need;

New manufacturing processes & equipment New working practices

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Table of Contents

ITP The market

Manufacturing technologies
Working practices Conclusion

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Manufacturing Technologies In house Welding Machining Materials Transversal technologies:

Measurement NDTs Tooling Automation Modelling

Outsourced Forging Casting Forming ...

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Welding Technology Modeling, validation and optimization

Development of simplified models that simulate the actual heat input. Modeling to predict distortion and residual stresses. Design of experiments: eliminate defects lack of fusion, bites, ...). Standardize repair methods.

Automation and process control

Introduction to online control for arc welding Complete automation. Improve NDTs techniques to detect complex defects (RX). Autonomous UST.

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Machining Technology
Lower cost & higher removal rates machining techniques (Ceramics and CBNs for Ni alloys, high performance milling for Ti). Mechanized end profiling for LPT discs. Product surface integrity vs cutting parameters. Drilling monitoring systems. Reduced number of set ups (multitask machines). Optimize alumina grinding for shafts and discs. Optimize broaching cutting parameters. Vibration prediction models for machine-tool-piece to optimize cutting conditions. After heat treatment residual stress modelling to predict deformations during machining.
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Measurement technologies
Reduce the need for CMM inspection; SPC, sampling. In process inspection Non-contact scanning Minimize the measurement cycle Revo probe technology

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Automation
Automated radiographic inspection, looking for a future integration with digital radiography Radial structures handling online Loading and pre-adjustment: NGV measurement on CMM EDM and grinding for NGV NGV autonomous manufacturing cell

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Tooling Technology

Required a technological leap Use of mechanical analysis tools available for optimizing geometry / weight and life estimation.

Explore new generation of tooling: pneumatic damping systems, pneumatic/hydraulic self centering systems, Quick clamping & release systems, ...

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Casting, Forging, Forming

Investment casting process modelling for product geometry and mould metal yield optimization.

Near net shape forgings. Roll forming for static components. Flow forming to substitute fabrications ...

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ITP The market Manufacturing technologies

Working practices
Conclusion

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Working practices - The lean Journey

Continuous waste elimination Create Flow Control & Sustaining Basic Stability

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The lean Journey: Basic Stability

Basic Stability

In a lean view each feature is a possibility to stop flow. Design for manufacturing Its a key tool to get flow!!

100% RFT in OP360 TBH T900

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The lean Journey: Basic Stability

Basic Stability

From 80 min to 30 min CO time reduction

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The lean Journey: Control & sustaining

Results example:

Control & Sustaining Basic Stability

TBHs welding M. Hours

WIP tracking Board

Cell Production Plan
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The lean Journey: Create flow

Create Flow

Control & Sustaining Basic Stability

VSM: A tool for pass from current to future flow by optimizing flow
Current NGVs Flow Future NGVs Flow

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Table of Contents

ITP The market Manufacturing technologies Working practices

Conclusion

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Summary
Better manufacturing technologies and the way they are used; Improve quality of existing products Creates new product opportunities Speeds up time to market Reduces both unit and non recurrent costs

therefore, their continuous development is a must to remain competitive.

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Building the bridge

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25th Anniversary IDEKOIK4

Manufacturing technologies as a key enabler for increasing competitiveness

Alvaro Vacas Cortadi
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BACK UP

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Advanced Manufacturing technologies in our sector

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Advanced Manufacturing technologies in our sector

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