Design of a large scale production system for aluminum GLARE sheets MSc project, Fokker Aerostructures Graduation 13/01/2015 Piet de Vries MSc. student Transport Engineering and Logistics

Overview of the presentation Introduction Methodology Analysis current state production Modelling future state production Results Conclusions & Recommendations

Handout presentatie 28-apr-17 Introduction Fokker Aerostructures Specialist in the design, development and manufacturing of lightweight structures for the aerospace and defense industry. Large Commercial Aircrafts Fokker Aerostructures produces GLARE panels for the Airbus A380. Business Jets Defense (EU and USA) Special Products Specialist in het ontwerpen, ontwikkelen en produceren van lichtgewicht modules voor de luchtvaart en defensie industrie. Large Commercial aircrafts: Airbus (A380, A350), Boeing (747/748, Large Cargo Freigther) Business Jets: Gulfstream (G550, G650), Dassault (Falcon 7X), Cessna (Citation Sovereign) Defense: NH Industries (NH90), Boeing (Apache, Chinook, C17), Lockheed Martin (F16, JSF) Special Products: Dutch Space (Ariane V), Lockheed Martin (Patriot), Royal Dutch Army (Shelters, E-lighters) Copyright Fokker Aerostructures B.V.

Introduction Glass Laminate Aluminum Reinforced Epoxy Handout presentatie 28-apr-17 Introduction GLARE Glass Laminate Aluminum Reinforced Epoxy GLARE panel production: GLARE consists of: Pretreated aluminum sheets Pre-impregnated fibers (prepreg) GLARE panel for the Airbus A380. The pretreated aluminum sheets and prepreg are laminated in a mold. The actual GLARE is formed in an autoclave under high pressure and at high temperature. Voorbehandelde sheet is geproduceerd en wordt aangevoerd aan de lay-up! Copyright Fokker Aerostructures B.V.

Introduction Production of GLARE sheets at Fokker Aerostructures Handout presentatie 28-apr-17 Introduction GLARE sheets Production of GLARE sheets at Fokker Aerostructures Storage raw material 1 Aluminum sheet production 2 Chemical treatment line 3 Bondprimer paint shop 4 Storage finished goods 5 De sheets moeten voorbehandeld worden om te zorgen voor voldoende binding tussen de prepreg en het aluminium. Het voorbehandelen bestaat ruwweg uit drie stappen: Sheet production Chemical treatment Aanbrengen van de bondprimer Vervolgens worden de sheets opgeslagen in een enorme voorraad. Copyright Fokker Aerostructures B.V.

Handout presentatie 28-apr-17 Introduction Current production system versus future demand Fokker Aerostructures produces for the Airbus A380 30 shipsets (set of panels for one aircraft) per year. Fokker wants to participate in upcoming high-rate aircraft production programs (2020). Expected demand is 300 shipsets per year. Current (small scale) production systems are not able to cope with these increasing and high volumes. Daadwerkelijke productie zal starten in 2020. Probleem: laatste zin Copyright Fokker Aerostructures B.V.

Handout presentatie 28-apr-17 Introduction High flexible, high volume against lower recurring costs Fokker Aerostructures therefore started the project GLARE Automation The aim is to show that a highly flexible (low response time), low cost and high volume production system for GLARE panels is possible The recurring costs of GLARE should be reduced significant (overall recurring costs should be reduced by 50%!) Possible cost savings to achieve a 50% reduction on recurring costs Recurring costs of GLARE production should be reduced significantly (step change) Copyright Fokker Aerostructures B.V.

Handout presentatie 28-apr-17 Introduction Scope, research goal and research questions Scope Production of pretreated aluminum sheets Objective “To show that highly flexible, low costs and high volume production of pretreated aluminum sheets is possible.” Research question “How to model a production system for pretreated aluminum sheets, which is capable to cope with high-rate aircraft production programs?” Binnen high-rate aircraft production programs vallen: highly flexible, low costs and high volume Modelling of a future state production system for high-rate aircraft production programs Copyright Fokker Aerostructures B.V.

Handout presentatie 28-apr-17 Methodology Research design Value stream mapping is used to analyze the current state production system The performance of the future state production system is measured by: Cycle time (non-value added and value added) Waiting time Work-in-progress (WIP) Lead time Response time (indicator for the flexibility of the system) Recurring costs of pretreated aluminum sheets are determined by three cost items: Material costs Labor costs Depreciation on investment Response time: The time between demand and delivery of a specific aluminum sheet; demanded by the lay-up process and delivered by the sheet production system. Copyright Fokker Aerostructures B.V.

Analysis current state production Value stream mapping Value stream map performed to identify the production times and waste in current state production Lead time and response time can be reduced by minimizing the waste Cycle time Lead time Response time 6.4 hours 31 days 19 hours Storage raw material 1 Aluminum sheet production 2 Chemical treatment line 3 Storage finished goods 5 Bondprimer paint shop 4 Waiting time: 13 days Waiting time: 17 days Om een hogere flexibiliteit te realiseren, moet de waste uit het productieproces geëlimineerd worden. Waste: inventories, waiting time, transportation, motion, over-processing, over-production and defects.

Modelling future state production Handout presentatie 28-apr-17 Modelling future state production Requirements from (internal) customer Requirements from the (internal) customer, the lay-up stations, are described and divided in: Product requirements: Some sheets have to be preformed Process requirements: Delivery of an unique sheet in 15 minutes. Maximum of 1 unique sheet per 12 hours. Production requirements: Yearly production of 193,500 sheets, with 129,600 flat and 63,900 preformed sheets. Product requirements: The requirements for the final product, the pretreated aluminum sheets Process requirements: The requirements for the production processes and especially the process which delivers the sheet to the lay-up station Production requirements: The required sheet production as requested by the lay-up station. The demand of the lay-up station is directly related to the production demand of the aircraft manufacturer. Copyright Fokker Aerostructures B.V.

Modelling future state production Handout presentatie 28-apr-17 Modelling future state production Future production systems Three future production systems are proposed: Production system A: Producing aluminum sheets with the current state Airbus A380 GLARE production technology. Production system B: Producing aluminum sheets from a lean manufacturing’s perspective with minimal waste and short lead times in an automated production environment. Production system C: Production is based on production system B, but the flexibility is increased (lower response time) by shifting the 2D milling process to the end of the production. Copyright Fokker Aerostructures B.V.

Modelling future state production Input and output variables Microsoft Excel is used to model future state production systems Input variables: Demand (# shipsets per year, sheet list) Effective machine hours (full-time production = 6,200 hours per year) Process times per resource Recurring costs variables (material waste, material costs, labor rate, investment per resource) Inventory variables (fixed costs per m2, return on inventory capital) Output: Required sheet production (number of flat and preformed sheets, total sheet area) Production times Inventory costs Recurring costs (based on the three cost items)

Results Production times – Lead time and response time Lead time is reduced by: Higher production rate Minimizing inventories Reducing non-value added activities Faster 2D milling machine Response time is reduced by: Waste reduction (lean) Shifting 2D milling process to end of production Production system C is highly flexible for flat sheets compared to the other production systems. Lead times 2e punt eigenlijk: minimizing waste

Results Recurring costs Current (A380) recurring costs are €65 per m2. High-rate production with A380 production technology results in recurring costs of € 64 per m2. Waste reduction and automation results in recurring costs of € 40 per m2. Shifting the 2D milling process to the end of the production reduces the recurring costs furthermore to € 38 per m2. - 42%

Results Relation between variables A sensitivity analysis is performed to determine the relations between the variables. To identify promising fields of study to reduce the recurring costs furthermore. Production system A: Reduce labor costs Reduce material cost price Reduce material waste (milling) Reduce investment Production system B: Production system C: Reduce material cost price Reduce material waste (milling) Reduce labor costs Reduce investment Om te bepalen op welke manier de recurring costs het meest gereduceerd kunnen worden! Belangrijk voor vervolgonderzoek!

Conclusions Research question “How to model a production system for pretreated aluminum sheets, which is capable to cope with high- rate aircraft production programs?” High rate aircraft production programs: high flexibility, low costs and high volume production Flexibility of future production system can be measured with the response time. Flexibility can be increased by shifting the 2D milling position to end of the production (response time of 12 minutes). Recurring costs can be determined by three cost items and can be mainly reduced by: Automation of the production processes (reduce labor costs) Decreasing the material cost price Decreasing the material waste Belangrijkste is: Het aantonen dat high flexible, low costs and high volume mogelijk is! Dat toont dit onderzoek aan! Tevens geeft dit onderzoek inzicht in waar je kosten zoveel mogelijk kunt besparen!

Recommendations Implement production system C: shift 2D milling process to the end of production. High flexible and low costs. Reduce recurring costs furthermore by reducing the material cost price and material waste of the sheets (reduce milling waste). To create a high flexible production system, preformed sheets should be omitted. More or less all the sheets can be delivered within 15 minutes – no finished goods inventory.

Design of a large scale production system for aluminum GLARE sheets MSc project, Fokker Aerostructures Graduation 13/01/2015 Piet de Vries MSc. student Transport Engineering and Logistics

Back-up 2014.TEL.7866.pdf Fokker_model_sheetmetal v4.7.xlsx A380_production_system.xlsx

Back-up Recurring costs reduction

Back-up Production times Production times 44,402 8,231 4,167 1,685 8,377 4,236 4,236

Back-up Overview recurring costs

Back-up Inventory costs