Transcript 5255-d2-manufacturing-engineering-presentation.ppt

Sophie BETTI
Florent DUPUY
Manufacturing Engineering
Presentation
BLMLII – June 2009
Manuf Engineering - Summary
I.
Manuf Engineering generalities
II. The 3 activities
III. Conceiver Manuf-Engineer
IV. Serial Manuf-Engineer
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
V. Technical Support
VI. The Digital Mock-Up
M.E. Movie
Page 2
Manuf Engineering
Manuf architect
Interface Role
Procurements/Logistics
Design
Office
Accounts Dpt
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Manuf
Engineering
Tools D.O.
& Methods
Work Study
Agent
Workshop
& Quality
Page 3
Manuf Engineering
From the product conception phase, the Manuf Engineering
PREpare
the Workshop realisation job
taking in account the productivity objectives : quality, costs, delays & security.
The Manuf Engineering
Imagines and Creates
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
the Operative
Methods and the Technical Instructions
used by the Workshop to
Manufacture and Assemble
the aircraft components.
Page 4
Manuf Engineering
The Manuf Engineering in the industrial Process:
Conceiver Manuf-Enginner 10%
Specify
Serial Manuf Engineer 60%
Define
D.O.
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Prepare
Launch
Definition
Dossier
Manufacture
Assemble
Workshop
As Prepared
Work Order
Technical
Support 30%
Certify
Deliver
Quality
P.Q.R.
A.I.R.
Page 5
Manuf Engineering
Each specific profession has:
- 1 process described in the Airbus cartography
 AOPM
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
- 1 skills and Airbus knowledges list
 Optimize Skills & « borne métier »
- 1 documentary referential
 @bcd, “borne métier”
Page 6
Specific profession details:
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Conceiver
Manuf-Engineer
Serial Manuf-Engineer
Technical Support
Manuf-Engineer’s
Major roles
Contributes to the product
definition and to the realisation
and check means
And
Evaluates the costs and the
industrialization cycles.
Elaborates the
industrialization
dossiers AND
Calculates
Proves and validates
the « as planned » and
the
« as prepared »
AND
Prepares the work generated
by the manufacturing problems
Information
Support
Pre-project
Pre-enquiry
Definition Dossier
Work order
Products and physical means
Work place
In operational team with the
A/C D.O. and the tooling D.O.
Manuf-Engineer office
Workshop
Results
Required Skills
- Industrial sharing plan
(manufacturing plan)
- Definition dossier
-Manufacturing techniques
-Files management
As prepared
-Validated « as prepared »
-Specific « troubles » dossier
-Configuration management
-Configuration management
-Manufacturing management
(GPAO)
-Manufacturing management
(GPAO)
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Manuf Engineering
Each specific profession is supported by the « Central
Manuf-engineering » which is in addition in charge of:
- projects axis
- harmonization
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
- between FAL’s
- within Airbus France
- within d’Airbus
- users job support
- surveillance
- strategy
Page 8
Manuf Engineering
The manuf-engineering in the industrial
PRE-Project
PRODUCTION CONCEPTION
PRODUCTION PREPARATION
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
MANUFACTURING TECHNICAL SUPPORT
Project Start
Basic A/C
definition
Concept
M1
M3
Program
Pre-Launch
M5
M2
M0
M4
Idea of the product Requirementat Production Concept
At A/C basic level
Decision
to conceive
Feasability Phase
Program
Launch
M7
M6
Marketing
Authorization
Conception Definition
Phase
Phase
Start of FAL
M9
M8
First chip
First
Flight
Entry Into
Service
M11
M10
First A/C PowerON
M13
M12
Certification
M14
End of
development
Serial
Phase
Development Phase
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Conceiver Manuf-Engineer
Ressources
A/C Definition
(buildings, machines, tools,
menpower…..)
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
3D digital mock-up
Macro ‘work order’
Assembly Process
Virtual Validation
Definition & Validation
Page 10
Conceiver Manuf-Engineer – A/C Definition
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The digital mock-up is the result of 3D numeric models (parts) assembly.
Page 11
Conceiver Manuf-Engineer - DMU
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The Manufacturing mock-up review: check the mountability of the
elements of definition: a/c + tools + buildings
Numeric simulation : virtual risks analysis
Page 12
Conceiver Manuf-Engineer
Virtual Validation
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The simulation allows the evaluation of complex systems
behaviour and to guarantee the elements integration
Page 13
Serial Manuf-engineer
The 6 main steps for the serial manuf engineer
Definition
Analysis
Process
Elaboration
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Risks
Analysis
Definition
Lock
& Technical writing
Delta 2:
Conf Manag
Process
Validation
Page 14
Serial Manuf-engineer : Definition Analyse
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
The definition or « plan » is composed of:
- the E.C.N.: Engineering Change Note
- the B.O.M. Bill of Material
- 2D drawings
- 3D Digital mock-up
The definition is analysed and, if a defect is detected the manuf-engineer
indicates it through a DQN (Design Query Note).
Then the definition is changed into the « as prepared view » :
1 PLAN = 1 work order
Page 15
Serial Manuf-engineer : process elaboration
Imaginer ou adapter un processus d’assemblage
- Mode opératoire = Liste des opérations à réaliser (successives ou en //)
avec le temps au rang 100 (t100), la compétence atelier, …
- Nomenclature = Liste des éléments utiles à l’assemblage
- éléments avionables : pièces, produits qualifiés, sous-ensemble, kit…
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
- éléments non avionables : produits de nettoyage, prédécoupés
(« pochoirs » de peinture) …
- Expression de besoin fonctionnel d’outillage
- Documents complémentaires (fiche d’instruction, Guide et relevés,
procédés utilisés…)
Préparer l’analyse des risques
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Serial Manuf-engineer : analyse de risques
Avec un représentant des métiers :
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Atelier
Qualité
Support technique
Ergonome
Agent d’Etude du Travail
Bureau d’etude Outillage
Logistique…
Dérouler le mode opératoire et lister les risques (humain et
produit) et défaillances / 5M
Chiffrer la criticité de chaque risque :
Gravité
Occurrence
Détectabilité
si >100  mise en place d’1 ou + DAQ
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Serial Manuf-engineer : autres activités
• Bloquer la définition :
- empêche le BE de modifier le dossier de définition concerné
- si modif impérative  le BE est obligé de contacter le préparateur
et « négocie » le rang d’application.
• Rédaction technique
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
une FI = « lire pour faire »
Structure harmonisée : sommaire, enchaînement des opérations,
état final attendu, position texte / illustration, lexique …
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Serial Manuf-engineer : Gestion de config: Delta2
Gestion de configuration = cohérence entre spec client et produit livré au client
Le préparateur est concerné par le « delta2 » qui est l’écart entre les phases
définir et préparer, une fois sa définition bloquée.
Spécifier
Définir
D2
Préparer
Lancer
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Fabriquer
Assembler
Attester
Livrer
Outils:
Maeva et Delta2 Eq (SA + LR)
Mega2 et Mega2 Eq (A380 + A400M)
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Serial Manuf-engineer : validation de processus
Valider les processus opératoires
-
L’enchaînement des opérations
La faisabilité
Les temps de réalisation
Les outillages utilisés et leurs fonctionnalités
etc, etc….
lors des premières applications série en Atelier
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
par la méthode dite des 5M.
Liste des intervenants:
 Atelier, Opérateur
 Préparateur / Support technique (Pilote)
 Support Qualité
 Support Logistique
 AET
 Bureau Outillage
Présence
obligatoire
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Serial Manuf-engineer : étapes du dossier de prépa
Prépa.
Ordo.
Prépa. ou ST
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Atelier + Qual.
+ Prépa.
Création du dossier de préparation
Lance l’OF
Passage automatique du statut de la gamme en
« processus en cours de validation »
Mettre en œuvre le processus
Vérifier la FVP et la renseigner
Examiner les résultats
Groupe de
validation
Processus
à valider
Processus
en cours
de
validation
Valider le processus, sinon débattre des
corrections à apporter
Qualité
Valider les outillages
Prépa.
Passer le statut de la gamme en
« processus validé »
Processus
validé
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Cascade du dossier de préparation
PROGAMME
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STATION
STATION
STATION
FONCTION MONTAGE
FONCTION MONTAGE
FONCTION MONTAGE
Validité
Validité
Validité
OPERATION
Gamme
OPERATION
Opératoire
OPERATION
Documents
Outillages
Processus
PIECE
EQUIPEMENT - FIN
CMS
ARTICLES ou OBJET
CONFIGURATION
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Technical Support
Support de proximité  situé à l’atelier
Il met au point le produit, le processus, les moyens et les
interfaces lors des premières utilisations et applications à l’atelier
Validation de Processus
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Valider un processus c’est:
- L’enchaînement des opérations
- La faisabilité
- Les temps de réalisation
- Les outillages utilisés et leurs fonctionnalités
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Technical Support
Il réagit aux aléas techniques (litiges, dérogations, OT de
parachèvements…).
Aléas de
production
Conforme à la
définition?
Oui
Litige / DQN
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Non
Anomalie
« démontable »
Oui
AM (Qualité)
Non (ex: perçage trop grand)
AM + Dérogation
(soumis à accord BE)
Page 24
Serial Manuf-engineer : in brief
Definition Dossier
Tool functional
Spec
New one or evolution of one
Imagine or
adapt the
process
Macro W.O.
PAT
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Production
Risks & defects
analysis
Up & Downs
Process
validated
yes
no
Process Validation ?
Update
as prepared view
Page 25
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
DMU – Digital Mock-up
Digital Mock-Up
Real A/C:
Page 26
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
DMU – Digital Mock-up
3D instruction sheet:
Page 27
DMU – Digital Mock-up
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Examples of Instruction Sheets in 3D animated / Hambourg
A380:
A350 Macro Assembly:
Page 28
Correspondance cascade BE-PROD
Cascade Bureau Etude
F531 10000 000
Cascade Production
EC
PROGA340
Tronçon 11 supérieur
F531 10018 000
TRD
STAT
FQD590
Liaison plancher /Casquette
FM
F53B100425
Poste de montage
RF
Sol
Val
Gamme
de
montage
Validités
F531 10066 000
Plan Sol de montage
OPE
© AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document.
Liaison C1/Plancher
F531.10066.000
Gamme de
fabrication
P/N
FIN
PQ
PIE
EQ
CMS
F531 10433 200
12MJ1
PQ 10050-050-00
Gousset
F531.10433.200.00
F-12MJ1
4988987847
Equipement
Mastic
CMS
CMSE
2014124708
634705300
Matière
ASNA30128600001
Tôle mince
634705300
PIE: élément magasinable ( S/Ens ou PE ) non affecté à un
avion
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