Gas Turbine Manufacture

25th Anniversary IDEKO – IK4 1

25th Anniversary IDEKO–IK4

Manufacturing technologies as a key enabler for increasing competitiveness in gas turbine manufacture

Alvaro Vacas Cortadi

25th Anniversary IDEKO – IK4 2

Table of Contents

• ITP

• The market & business

• Manufacturing technologies

• Working practices

• Conclusion

25th Anniversary IDEKO – IK4 3

Table of Contents

• ITP

• The market & business

• Manufacturing technologies

• Working practices

• Conclusion

25th Anniversary IDEKO – IK4

a a

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ITP – Industria de Turbo Propulsores S.A.

Global market

Production in €, $ & ₤

Low cost & high value added

Internationalization LPTs design and make

Engines assembly & testing

Engines maintenance

Capabilities ITA ; pipes

PCB; investment castings

Vertical integration

• 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

25th Anniversary IDEKO – IK4

ITP Zamudio

PCB ITP Ajalvir

ITP UK ITR

ITABenchmark Make

Buy ProtectCompe

titiven

ess

Criticality

ITP Operations – MAKE/BUY

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Table of Contents

• ITP

• The market & business

• Manufacturing technologies

• Working practices

• Conclusion

25th Anniversary IDEKO – IK4

Aircraft manufacturer (OEM Aircraft)

Airliner

Raw material suppliers

Maintenance Centers

OEMs Engine

Tier 1 Partnerts

Tier 2 Suppliers

ManufacturingAircraft/Engine

Parts

Spare engine parts

EnginesAircrafts & engines

Services

Maintenance

Aeronautical market – commercial aviation

25th Anniversary IDEKO – IK4

Globalization - Airlines

25th Anniversary IDEKO – IK4

Globalization - Aircrafts

25th Anniversary IDEKO – IK4

Globalization - Engines

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The situation of the industry – global recovery

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Future products

25th Anniversary IDEKO – IK4

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

Environmental requirements

25th Anniversary IDEKO – IK4

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

25th Anniversary IDEKO – IK4

ANÁLISIS INTERNO

EEUU Mexico Brasil ChinaIndiaPolonia

100%

80%

70%

90%

125%

Source: ICEX 2009 and ITP´s estimates

España

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

60%

Labour costs vs competitiveness

Spain competitivines ranking has fallen from 29th to 33th from

2008-2009 period to 2009-2010.Source; World Economic Forum

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Supply chain rationalization

Rolls-Royce - Number of suppliers

0

50

100

150

200

250

300

350

400

450

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 atLCCs

≈ 45% RRSP ≈ 60 suppliers 64% of costs in US$ ≈ 20% of cost is located atLCCs

• Reduction in the number of suppliers.• Increase the risk & revenue partnership content.• Increase the dollar content.• Increase the Low Cost Countries content.

25th Anniversary IDEKO – IK4

ANÁLISIS INTERNO

Mexico & China as major recipients of Aero investments

Low Cost Countries (LCC)

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Low Cost Countries – Mexico sample

25th Anniversary IDEKO – IK4

MAKE – efficiency, $MAKE - InsourcingBUY - LCC Sourcing

Make vs buy – Rolls Royce

25th Anniversary IDEKO – IK4

ANÁLISIS INTERNO

MAKE – efficiency, $MAKE - InsourcingBUY - LCC Sourcing

Make vs buy – General Electric

25th Anniversary IDEKO – IK4

ANÁLISIS INTERNO

MAKE – efficiency, $MAKE - InsourcingBUY - LCC Sourcing

Make vs buy – Snecma

25th Anniversary IDEKO – IK4

ANÁLISIS INTERNO

MAKE – efficiency, $MAKE - InsourcingBUY - LCC Sourcing

..

Make vs buy – MTU

25th Anniversary IDEKO – IK4

ANÁLISIS INTERNO

.

MAKE – efficiency, $MAKE - InsourcingBUY - LCC Sourcing

Make vs buy – Avio

25th Anniversary IDEKO – IK4

ANÁLISIS INTERNO

MAKE – efficiency, $MAKE - InsourcingBUY - LCC Sourcing

Make vs buy – ITP

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MARKET

• Global recovery → Increased Volumes.

• Buyer driven market.

• Escalating Oil & metal prices.

• Dollar vs €uro volatility.

• Labour costs increasing.

• Market globalization.

• LCCs industry development.

• Environmental objectives.

Market & Business Challenges

BUSINESS

• Process capability & delivery adherence.

• Reduced Unit Cost.

• Reduced Tooling Costs.

• Make vs Buy policies.

• Supply chain rationalization

• Novel engine & components architectures.

• Reduced time to market.

• New materials and processes.

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

25th Anniversary IDEKO – IK4

Manufacturing Technologies

In house• Welding• Machining• Materials • Transversal technologies:

• Measurement• NDTs• Tooling• Automation• Modelling

Outsourced• Forging• Casting• Forming• ...

25th Anniversary IDEKO – IK4

• Introduction to online control for arc welding

• Complete automation.

• Improve NDTs techniques to detect complex defects (RX).

• Autonomous UST.

Automation and process control

Welding Technology

• 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.

Modeling, validation and optimization

25th Anniversary IDEKO – IK4

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.

25th Anniversary IDEKO – IK4

Measurement technologies

• Reduce the need for CMM inspection;– SPC, sampling.

– In process inspection

– Non-contact scanning

• Minimize the measurement cycle– Revo probe technology

25th Anniversary IDEKO – IK4

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

25th Anniversary IDEKO – IK4

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, ...

25th Anniversary IDEKO – IK4

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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Table of Contents

• ITP

• The market

• Manufacturing technologies

• Working practices

• Conclusion

25th Anniversary IDEKO – IK4

Continuous waste elimination

Create Flow

Control & Sustaining

40

Working practices - The lean Journey

Basic Stability

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The lean Journey: Basic StabilityBasic

Stability

In a lean view each feature is a possibility to stop flow.

Design for manufacturing It’s a key tool to get flow!!

100% RFT in OP360 TBH T900

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The lean Journey: Basic StabilityBasic

Stability

From 80 min to 30 min CO time reduction

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The lean Journey: Control & sustainingControl & Sustaining

Basic Stability

Cell Production Plan

WIP tracking Board

Results example:

TBH’s welding M. Hours

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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 NGV’s Flow Future NGV’s Flow

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Table of Contents

• ITP

• The market

• Manufacturing technologies

• Working practices

• Conclusion

25th Anniversary IDEKO – IK4 46

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 IDEKO–IK4

Manufacturing technologies as a key enabler for increasing competitiveness

Alvaro Vacas Cortadi

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BACK UP

25th Anniversary IDEKO – IK4 50

Advanced Manufacturing technologies in our sector

25th Anniversary IDEKO – IK4 51

Advanced Manufacturing technologies in our sector