1. 7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Airbus practices for maintainability and human simulations Movie Workshop 7 th and 8 th January 2005, LAAS-CNRS. Presented by Christophe Le Roy Project leader in research on tools and devices for DMU exploitation

2. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 2 Content Airbus:  the organization,  the production and engineering sites,  ACE : Airbus Concurrent Engineering. Simulation activities:  the use of the Digital Mock-Up,  assembly – disassembly / maintainability / human simulations. Research activities:  the project SAMIRA. Conclusions.

3. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 3 Airbus | The organization. 20%80% AIRBUS FRANCE AIRBUS DEUTSCHLAND AIRBUS ESPAÑA AIRBUS UK GIE transformed into Airbus Integrated Company since July 11, 2001 Adding value through integration.

4. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 4 Airbus | Production and engineering sites. * Approximate figures July 2004 Airbus direct workforce in Europe * Headquarters:  6/7%employees Airbus France:  33 % employees Airbus Germany:  37 % employees Airbus UK:  18 % employees Airbus Spain:  5/6 % employees  50,000 people Airbus direct workforce in Europe * Headquarters:  6/7%employees Airbus France:  33 % employees Airbus Germany:  37 % employees Airbus UK:  18 % employees Airbus Spain:  5/6 % employees  50,000 people St Nazaire Toulouse Broughton Nantes Filton Madrid Méaulte Illescas Puerto Real Laupheim Stade Hamburg Bremen Varel Buxtehude Nordenham  50,000 people sharing on 16 competences centers. Production sites Major engineering sites

5. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 5 Airbus | Production system. AIRBUS-France AIRBUS-Deutschland AIRBUS-UK Belairbus AIRBUS-España Production sharing by the Centres of Competence.

6. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 6 Airbus | ACE : AIRBUS Concurrent Engineering To develop a new aircraft program, all functions must join their skills and efforts… ACE is a key integration project and enabler for the new aircraft. Strong impact on tools, processes and methods. MISSION: processesmethods tools Providing Airbus with a competitive advantage by establishing integrated and efficient processes, methods and tools along the whole product life cycle. SCOPE: trans-national organization Integrate data and information related to the Airbus development process in the trans-national organization. Major focus on new aircraft programs.

7. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 7 Digital Mock-Up? What is a Digital Mock-Up?  A Digital Mock-Up is a simulation based on numerical and/or digital models that represents partially or globally a product or part of a product (airframe, systems, avionics, …). Why using a Digital Mock-Up?  To support the analysis of the product during its different phases (project, feasibility, definition, post EIS).  DMU is used to ease design, understanding, validation, modification, information, selling, support & maintenance,...  DMU is used to replace partially or totally the physical mock-up.

8. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 8 Digital Mock-Up applications. FeasibilityConceptDefinitionDevelopmentSeries M3M5M7 M13 Numerical Command Tooling Master Geometry Assembly Instructions Tooling Principles Tooling Space Allocation Tooling Frontier Models Manufacturing Plan Industrialization Supportability Analysis Supportability Discrepancies Support Specification Support Objectives Support Master Geometry Frontier Models Definition Model Space Allocation Stress Design Reference Base Design Principles Definition Dossier Aircraft Systems ArchitectureParts Tools Factory

9. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 9 Simulation activities. Assembly/disassembly simulation Assembly/disassembly simulation.  Verify if a part or an assembly (set of parts) can be assembled in / disassembled from its environment.  Trajectory simulation performed by a design engineer or/and a maintainability actor. Preliminary simulation Maintainability simulation Maintainability simulation.  Verify if a part or an assembly can be mounted / dismounted by an operator or a manufacturing system (tools, robots, …).  Trajectory, sequence of manipulation, validation by maintainability experts. Human simulationrocess definition and validation Human simulation / process definition and validation.  Simulate that a part or an assembly can be mounted / dismounted by an operator or a manufacturing system.  Complete human / manufacturing simulation defined by a maintainability / manufacturing expert. Dynamic simulation Static simulation

10. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 10 Human simulation Examples | Human simulation. Validate an assembly operation with manikin. The manufacturing process & environment is planed, visualized and optimised in one tool. Cost reduction for recurring cost by evaluation of the best process concept Objectives Validation of news functionalities (Delmia V5). Check the operations of assembly according to the configuration plane in the post (access and the ergonomics operations). Check collisions & movements with equipment (tools). Objectives Validation of news functionalities (Delmia V5). Check the operations of assembly according to the configuration plane in the post (access and the ergonomics operations). Check collisions & movements with equipment (tools). Project Benefits Anticipation of the ergonomic problems for the operator (better comfort to work). Better hand tooling/Aircraft parts integration (use of check collision). Lead time reduction & rapid aircraft maturity. Less effort for documentation (use of 3D mock-up for technical publication). Project Benefits Anticipation of the ergonomic problems for the operator (better comfort to work). Better hand tooling/Aircraft parts integration (use of check collision). Lead time reduction & rapid aircraft maturity. Less effort for documentation (use of 3D mock-up for technical publication).

11. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 11 Examples | Process Definition & Validation. Objectives Software validation (Delmia V5). Validate the process of assembly and unassembly. Check collisions & movements with equipment (Jigs & Tools). Objectives Software validation (Delmia V5). Validate the process of assembly and unassembly. Check collisions & movements with equipment (Jigs & Tools). Project Benefits Clashes at section movement discovered and alternative proposed. Reduction of tool cost (more than 10 major problems discovered). On dock safety regulations approved. First time right achieved (planned). Better associativity between data (very useful in case of modification). Project Benefits Clashes at section movement discovered and alternative proposed. Reduction of tool cost (more than 10 major problems discovered). On dock safety regulations approved. First time right achieved (planned). Better associativity between data (very useful in case of modification). Jigs and human assembly processes are validated for a subassembly. The manufacturing engineer is supported by doing the process optimisation. Planning safety and quality is increased. Validation of the assembly of a big structure.

12. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 12 Simulation activities | Today status. DMU status for geometrical engineering design and for manufacturing process.  Until 1998, all our previous aircraft programs have been fully developed by using the physical mock-up.  The A340-500/600 and A380 programs have been mainly developed by using the digital mock-up based on the Concurrent Engineering method (engineering simulation, digital factory). –Integration between aircraft engineering and industrialization engineering. How to improve the today status?  Do more simulations?  Improve integration in our business processes and methods?  Improve tools : accuracy, rapidity,automation?

13. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 13 Research activity on simulation (1/4). Simulation issue.  Engineering.  Manufacturing.  Support. …… Request for simulation support No Simulation expert Yes Interactive process Automated process Simulation support Resolution. Solution. Find the compromise between:  resources,  time,  methods,  processes,  competencies, ...

14. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 14 Research activity on simulation (2/4). Interactive simulation process. SAMIRA – SimulAtion de Maintenance Interactive avec Retour hAptique / Intuitive manipulation using force feedback (EADS CCR). History in brief.  1998 - 2001 : PhD thesis on interaction and force feedback (EADS CCR).  January 2004 : new research activity with 6D force feedback : SAMIRA II.  January 2004 : operational deployment of SAMIRA I based on a SpaceBall / SpaceMouse.  Great interest for Airbus !  Force feedback in 3D : poor, not useful.  Intuitive manipulation with SpaceBall / SpaceMouse : great !  June 2001 : GO for a first prototype with 3D force feed-back.  April 2002 : first demonstration SAMIRA v1.0.  September 2002 : in-situ tests and validation (v1.1).  2003 : general improvements.

15. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 15 Research activity on simulation (3/4). Interactive simulation process. SAMIRA I SAMIRA I functionalities.  Object manipulation out of collision, trajectories out of collision.  Intuitive manipulation. –6D manipulation (SpaceBall / SpaceMouse / PHANToM). –Interactive limitations of some Degrees of Freedom on request. –Interactive reference frame change. –…  Visual and sound information. –Contact points. –Parts in contact highlighted. –Stereoscopic view. –…  Force feedback in 3D : poor, not useful.  Intuitive manipulation with SpaceBall / SpaceMouse : great ! SAMIRA I short

16. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 16 Research activity on simulation (4/4). Interactive simulation process. SAMIRA II SAMIRA II – force feedback in 6D (EADS CCR – DCR/ITP). SAMIRA II integrates:  Digital Mock-Up.  Interactive 3D visualization (Virtools).  Physics/dynamics (Havok, …).  Collision detection.  Intuitive manipulation 6D (SAMIRA I learning).  Force feedback 6D (Virtuose 6D from Haption). SAMIRA allows:  Early simulation.  Relevant physical / mechanical interaction with the product.  Real intuitive movements.  New metaphor of interaction (touch sense).  Force feedback in 6D : great ! SAMIRA II Bourget

17. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 17 Conclusion | What optimal solution? Classical simulation tools are used all along the definition and the development processes based on the Digital Mock-Ups. Force feedback and simulation of mechanical physics offer a perfect mechanical understanding of the DMU. Automatic path planning tools have a really great potential.  Kineo Path Planner (Kineo CAM) / LAAS researches. AccuracyEasiness Mech. perception Rapidity Classical simulation tools +–+– Interactive simulation with force feedback ++ + Automatic simulation process ++ –

18. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 7th and 8th January 2005Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1Page 18 This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by the delivery of this document and the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.