1. Manufacturing Engineering Presentation BLMLII – June 2009 Sophie BETTI Florent DUPUY

2. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 2 Manuf Engineering - Summary I. Manuf Engineering generalities II. The 3 activities III. Conceiver Manuf-Engineer IV. Serial Manuf-Engineer V. Technical Support VI. The Digital Mock-Up M.E. Movie

3. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 3 Manuf Engineering Manuf architect Interface Role Manuf Engineering Workshop & Quality Design Office - Procurements/Logistics Accounts Dpt - Tools D.O. & Methods Work Study Agent

4. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 4 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 the Operative Methods and the Technical Instructions used by the Workshop to Manufacture and Assemble the aircraft components.

5. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 5 Certify Deliver Manufacture Assemble Manuf Engineering The Manuf Engineering in the industrial Process: Technical Support 30% Definition Dossier Prepare Launch Define Specify Conceiver Manuf-Enginner 10% Serial Manuf Engineer 60% As Prepared Work Order P.Q.R. A.I.R. D.O. Workshop Quality

6. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 6 Manuf Engineering Each specific profession has: - 1 process described in the Airbus cartography  AOPM - 1 skills and Airbus knowledges list  Optimize Skills & « borne métier » - 1 documentary referential  @bcd, “borne métier”

7. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 7 Specific profession details: Manuf-Engineer’s Major roles Information Support Results Work place Required Skills Serial Manuf-EngineerTechnical Support Contributes to the product definition and to the realisation and check means And Evaluates the costs and the industrialization cycles. Pre-project Pre-enquiry -Manufacturing techniques -Files management - Industrial sharing plan (manufacturing plan) - Definition dossier In operational team with the A/C D.O. and the tooling D.O. Elaborates the industrialization dossiers AND Calculates Definition Dossier -Configuration management -Manufacturing management (GPAO) As prepared Manuf-Engineer office Proves and validates the « as planned » and the « as prepared » AND Prepares the work generated by the manufacturing problems Work order Products and physical means -Validated « as prepared » -Specific « troubles » dossier Workshop Conceiver Manuf-Engineer -Configuration management -Manufacturing management (GPAO)

8. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 8 Manuf Engineering Each specific profession is supported by the « Central Manuf-engineering » which is in addition in charge of: - projects axis - harmonization - between FAL’s - within Airbus France - within d’Airbus - users job support - surveillance - strategy

9. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 9 Manuf Engineering The manuf-engineering in the industrial PRE-Project PRODUCTION CONCEPTION PRODUCTION PREPARATION MANUFACTURING TECHNICAL SUPPORT Serial Phase Development Phase Definition Phase M7 Program Launch M6 Marketing Authorization End of development M14 M13 Entry Into Service M9 Start of FAL M8 First chip M11 First Flight Program Pre-Launch M5 Certification M12 First A/C PowerON M10 Basic A/C definition Concept M3 Project Start M1 Conception Phase Feasability Phase Idea of the product to conceive M0 Requirementat At A/C basic level M2 M4 Production Concept Decision

10. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 10 Conceiver Manuf-Engineer Assembly Process Definition & Validation Ressources (buildings, machines, tools, menpower…..) A/C Definition 3D digital mock-up Virtual ValidationMacro ‘work order’

11. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 11 Conceiver Manuf-Engineer – A/C Definition The digital mock-up is the result of 3D numeric models (parts) assembly.

12. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 12 The Manufacturing mock-up review: check the mountability of the elements of definition: a/c + tools + buildings Numeric simulation : virtual risks analysis Conceiver Manuf-Engineer - DMU

13. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 13 Conceiver Manuf-Engineer Virtual Validation The simulation allows the evaluation of complex systems behaviour and to guarantee the elements integration

14. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 14 Definition Lock Risks Analysis Process Elaboration Definition Analysis Delta 2: Conf Manag Serial Manuf-engineer The 6 main steps for the serial manuf engineer & Technical writing Process Validation

15. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 15 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 Serial Manuf-engineer : Definition Analyse

16. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 16 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… - 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

17. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 17 Avec un représentant des métiers : 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 Occurrencesi >100  mise en place d’1 ou + DAQ Détectabilité Serial Manuf-engineer : analyse de risques

18. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 18 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 une FI = « lire pour faire » Structure harmonisée : sommaire, enchaînement des opérations, état final attendu, position texte / illustration, lexique …

19. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 19 Serial Manuf-engineer : Gestion de config: Delta2 Fabriquer Assembler Attester Livrer Préparer Lancer Définir Spécifier 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. Outils: Maeva et Delta2 Eq (SA + LR) Mega2 et Mega2 Eq (A380 + A400M)

20. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 20 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 par la méthode dite des 5M. Liste des intervenants:  Atelier, Opérateur  Préparateur / Support technique (Pilote)  Support Qualité  Support Logistique  AET  Bureau Outillage Serial Manuf-engineer : validation de processus Présence obligatoire

21. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 21 Serial Manuf-engineer : étapes du dossier de prépa Création du dossier de préparation Lance l’OF Prépa. Ordo. Processus à valider Passer le statut de la gamme en « processus validé » Prépa. Processus validé 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 Valider le processus, sinon débattre des corrections à apporter Valider les outillages Prépa. ou ST Atelier + Qual. + Prépa. Groupe de validation Qualité Processus en cours de validation

22. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 22 Cascade du dossier de préparation PROGAMME STATION FONCTION MONTAGE Validité OPERATION Validité OPERATION Validité OPERATION PIECE EQUIPEMENT - FIN CMS ARTICLES ou OBJET CONFIGURATION Documents Outillages Gamme Opératoire Processus

23. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 23 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 Valider un processus c’est: - L’enchaînement des opérations - La faisabilité - Les temps de réalisation - Les outillages utilisés et leurs fonctionnalités

24. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 24 Technical Support Il réagit aux aléas techniques (litiges, dérogations, OT de parachèvements…). Aléas de production Conforme à la définition? Litige / DQN Anomalie « démontable » AM + Dérogation (soumis à accord BE) Non (ex: perçage trop grand) AM (Qualité) Non Oui

25. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 25 Serial Manuf-engineer : in brief Definition Dossier New one or evolution of one Imagine or adapt the process Tool functional Spec Macro W.O. Production Up & Downs Process Validation ? Risks & defects analysis Update as prepared view noyes Process validated PAT

26. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 26 DMU – Digital Mock-up Digital Mock-Up Real A/C:

27. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 27 DMU – Digital Mock-up 3D instruction sheet:

28. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 28 Examples of Instruction Sheets in 3D animated / Hambourg A380: A350 Macro Assembly: DMU – Digital Mock-up

29. © AIRBUS FRANCE S.A.S. All rights reserved. Confidential and proprietary document. Page 29 F531 10000 000 Tronçon 11 supérieur F531 10018 000 Liaison plancher /Casquette F531 10066 000 Liaison C1/Plancher F531 10433 200 Gousset ASNA30128600001 Tôle mince 12MJ1 Equipement 634705300 PQ 10050-050-00 Mastic EC TRD PQ Matière P/N Plan Sol de montage FIN Sol RF Poste de montage Validités Correspondance cascade BE-PROD Cascade ProductionCascade Bureau Etude PIE: élément magasinable ( S/Ens ou PE ) non affecté à un avion F531.10433.200.00 2014124708 PROGA340 FQD590 F53B100425 Val F-12MJ1 634705300 F531.10066.000 STAT FM OPE PIE CMS CMSE EQ 4988987847 CMS Gamme de montage Gamme de fabrication