David Muñoz, Lean ExpertSilvia Pascual, Lean ExpertOctober 25th, 2017

AIRBUS DS LEAN JOURNEY TO ACCELERATE INNOVATION

Contents

The Company Enabling Innovation Lean Journey LPD- Case Study Future Challenges

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation2

Airbus We Make it Fly

Airbus is the largest aeronautics and space company in Europe and a worldwide leader.

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation3

Airbus Defence and Space

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation4

Strong, innovative and customer focused

Europe’s #1in defence and space with € 11.9 bn revenues in 2016

Investing in growth € 332 million spent on R&D in 2016.

Future-proofstrong growth in order intake, an order book above € 41.5 bn

Military Aircraft Space SystemsCommunications, Intelligence & Security Unmanned Aerial Systems

Enabling Innovation

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation5

The Lean Journey

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation6

• Vision & Roadmap• Governance Model

• Buy-in CEO• Kick-off sessions

• Lean Network (LE, CA)• 50% Visual Management

• Kaizen pilots (E2E)

• Lean Objectives B.II, B.III & B.IV• Lean Improvers

• Hoshin Kanri• 80% Visual Management• Problem Solving Pilots

• Kaizen (Business Needs)

• Lean Objectives B.V• Hoshin Kanri alignment with VM

• >90% Visual Management• 30% PPS

• Kaizen (Top Improvement Priorities)

• 100% Visual Management• 50% PPS

• Pilots Quality Excellence• Kaizen

• LPD pilots

• Quality Excellence• LPD Lean Thinking

• Lean Routines• LPD SBCE

• Extend LPD • Lean Innovation

NOV. 2011

2012

20132014

2015

2016

20172018+

• Virtual Visual Management• Quality Excellence

• E2E Missions• LPD SBCE pilots

LPD at Airbus DS

October 26th, 2017 Airbus DS Lean Journey to Acceletare Innovation7

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation8

LPD in Airbus DS –Best Practice

Innovation

Agility

Adaptability to requirement changes

SBCE

Time constrains

Budget constrains

Lack of direct interface with customer

Fuzzy requirements

Few suppliers available

No existing experience in different technologies

Regulations

LPD in Airbus DS –Best Practice – The process

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation9

ConvergenceScoping VoC T/O& Open Points

21 3 4 5

Convergence PlanningTrade Offs reviews

Trade offs

TO Decision Table

Incompatibility Matrix

Trade-offs

IDName

Kepner

TregoeKT Result

Selected

SolutionRationale

Justification (Action carried out,

Dependencies…)

A7 Cooling Yes Alternative B B (out of coffin)- maintainance easier

- less wightPendiond resistance estimation

A0Mission Power

Generator selectionYes Alternative C A (RED)

- achieve performance

- less technical risk

- certified

To be considered as añternatives:

- LYCOMING (possible extra cost)

- TEOS (high risk)

B2a Location Yes Alternative CC (FWD Cargo

Bay)

- centered

- less weihgt (compacted)

-less complexity (compacted)

Review A solution

B5b Ventilation intake Yes Alternative B B

- Simplicity

- less weight and cost

- less aerodinamics impact

B5cCompartment

ventilation rampsYes Alternative B B

- Simplicity

- less weight and cost

- mantainance

A solution can also be considered

B6aVentilation on ground

MPUYes Alternative B B

- Indedenpednt of systems

- Taxi operation

- Simplicity

- Considered external air as intake source

- if ventilation is not used in TAXI, Solution B to

be considered

B6bVentilation on ground

APUYes Alternative A A

- Done by Manufactured

- Included in price

A4 Exhaust No Alternative B B - Ease of installation

A8Cooling Electrical

GeneratorNo Alternative A A

- Best choice using technical

aspects

- If the oil is different, there are different peaks

of temperature, contamination….-> Could be

neccesary to review B solution

A9a Gearbox Supplier No Alternative A A

A9b Gearbox Regulation No Alternative B B

B1 Fuel architecture No Alternative A A

B2b Enclosure No Alternative B B- Maintainance

- Safety

Consider A solution in case of 4 engines (2

coffins of 2 engines)

B5a Air Supply (for Diesel) No Alternative B B

B5a Air Supply (for APU) No Alternative C C

B11 Generators Yes Alternative C

C (115 KVA)

APU A330

SAFRAN

- In service operation

-Self-contained

- Experienced in 115 RED

- Experienced with suppliers

2xRE

D-A3

EN

GIN

ES

2xTE

DS E

NGIN

ES

3xCM

-300

ENG

INES

3xW

ANKE

L ENG

INES

4xLY

COM

ING

ENGI

NES

APU

P&W

787

Hi-R

AT

Inte

grat

ed w

ith th

e A/

C

Dedi

cate

d

Pres

suriz

ed Z

one

/ Dist

ribut

ed in

bot

h Ca

rgo

Bays

/ 2x

RED-

A3/T

EDS

ENGI

NES

Pres

suriz

ed Z

one

/ Dist

ribut

ed in

bot

h Ca

rgo

Bays

/ 3x

CM-

300/

WAN

KEL E

NGIN

ES

Pres

suriz

ed Z

one

/ Dist

ribut

ed in

bot

h Ca

rgo

Bays

/

4xLY

COM

ING

ENGI

NES

Pres

suriz

ed Z

one

/ Al

l MPU

in o

ne C

argo

Bay

/

2xRE

D-A3

/TED

S EN

GIN

ES

Pres

suriz

ed Z

one

/ All

MPU

in o

ne C

argo

Bay

/ 3x

CM-

300/

WAN

KEL E

NGIN

E

Pres

suriz

ed Z

one

/ All

MPU

in o

ne C

argo

Bay

/ 4x

LYCO

MIN

G

ENGI

NES

Non-

Pres

suriz

ed Z

one

/ CLG

Bay

/ 2x

RED-

A3/T

EDS

ENGI

NES

Non-

Pres

suriz

ed Z

one

/ CLG

Bay

/ AP

U P&

W

Non-

Pres

suriz

ed Z

one

/ Bel

ly F

airin

gz+C

LG B

ay /

3xCM

-

300/

WAN

KEL E

NGIN

ES

Non-

Pres

suriz

ed Z

one

/ Bel

ly F

airin

gz+C

LG B

ay /

APU

P&W

Non-

Pres

suriz

ed Z

one

/ Ext

erna

l / F

US (H

i-RAT

)

Non-

Pres

suriz

ed Z

one

/ Ext

erna

l / W

ing

(Hi-R

AT)

Non-

Pres

suriz

ed Z

one

/ Int

erna

l / H

i-RAT

Sim

ple

shar

ed c

offin

(Die

sel E

ng.)

Inde

pend

ent c

offin

(Die

sel E

ng.)

Sim

ple

shar

ed c

offin

(APU

)

Inde

pend

ent c

offin

(APU

)

Exte

rnal

Inst

alla

tion

(Hi-R

AT)

Exte

rnal

One

uni

que

tube

Exte

rnal

Sev

eral

tube

s

Exte

rnal

Air

Supp

ly (D

iese

l Eng

.)

Cabi

n Ai

r sup

ply

(Die

sel E

ng.)

Exte

rnal

Air

Supp

ly (A

PU)

Cabi

n Ai

r sup

ply

(APU

)

Sing

le in

take

(Die

sel E

ng.)

Mul

tiple

inta

ke (D

iese

l Eng

.)

Sing

le in

take

(APU

)

Mul

tiple

inta

ke (A

PU)

Onl

y Ve

ntila

tion

/ Act

uate

d ra

mps

Onl

y Ve

ntila

tion

/ N

on a

ctua

ted

ram

ps

Onl

y Ve

ntila

tion

+ Co

olin

g / A

ctua

ted

ram

ps

Onl

y Ve

ntila

tion

+ Co

olin

g / N

on a

ctua

ted

ram

ps

Ejec

tors

(Die

sel E

ng.)

Vent

ilato

rs (D

iese

l Eng

.)

Exte

rnal

sour

ce (D

iese

l Eng

.)

Ejec

tors

(APU

)

Vent

ilato

rs (A

PU)

Exte

rnal

sour

ce (A

PU)

MPU

hea

t exc

hang

er w

ithin

the

coffi

n - A

mbi

ent A

ir

MPU

hea

t exc

hang

er o

ut o

f the

cof

fin

MPU

hea

t exc

hang

er w

ithin

the

coffi

n - C

abin

Air

Shar

ed w

ith M

PU

Dedi

cate

d

MPU

Sup

ply

Inde

pend

et

With

regu

latio

n (v

aria

ble

mul

tiplic

atio

n)

With

out r

egul

atio

n (fi

xed

mul

tiply

)

115

VFG

(Die

sel E

ng.)

270

VDC

(Die

sel E

ng.)

115

CFG

(Die

sel E

ng.)

230

VFG

(APU

)

115

V (H

i-RAT

)

2xRED-A3 ENGINES

2xTEDS ENGINES

3xCM-300 ENGINES

3xWANKEL ENGINES

4xLYCOMING ENGINES

APU P&W 787

Hi-RAT

Integrated with the A/C c c c c nc

Dedicated

Pressurized Zone / Distributed in both Cargo Bays / 2xRED-

A3/TEDS ENGINESc nc nc nc nc c

Pressurized Zone / Distributed in both Cargo Bays / 3xCM-

300/WANKEL ENGINESnc c nc nc nc c

Pressurized Zone / Distributed in both Cargo Bays /

4xLYCOMING ENGINESnc nc c nc nc c

Pressurized Zone / All MPU in one Cargo Bay /

2xRED-A3/TEDS ENGINESc nc nc nc nc c C Compatible

Pressurized Zone / All MPU in one Cargo Bay / 3xCM-

300/WANKEL ENGINEnc c nc nc nc c NC Not compatible

Pressurized Zone / All MPU in one Cargo Bay /

4xLYCOMING ENGINESnc nc c nc nc c ? Unkknown Compatibil ity, Stil l under investigation

Non-Pressurized Zone / CLG Bay / 2xRED-A3/TEDS ENGINES c nc nc nc nc c Option rejected

Non-Pressurized Zone / CLG Bay / APU P&W nc nc nc c nc cNon-Pressurized Zone / Belly Fairingz+CLG Bay / 3xCM-

300/WANKEL ENGINESnc c nc nc nc c

Non-Pressurized Zone / Belly Fairingz+CLG Bay / APU P&W nc nc nc c nc c

Non-Pressurized Zone / External / FUS (Hi-RAT) nc nc nc nc c nc

Non-Pressurized Zone / External / Wing (Hi-RAT) nc nc nc nc c nc

Non-Pressurized Zone / Internal / Hi-RAT nc nc nc nc c nc

Simple shared coffin (Diesel Eng.)

Independent coffin (Diesel Eng.) c c c nc nc c nc nc nc c c c c nc c nc nc nc nc

Simple shared coffin (APU)

Independent coffin (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc

External Installation (Hi-RAT) nc nc nc nc c nc nc nc nc nc nc nc nc nc nc nc c c c

External One unique tube

External Several tubes c c c c nc c c c c c c c c c c c nc nc nc c c nc

External Air Supply (Diesel Eng.)

Cabin Air supply (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c

External Air Supply (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c

Cabin Air supply (APU)

Single intake (Diesel Eng.) c c c nc nc c nc nc nc c c c c nc c nc nc nc nc c nc nc c c c nc

Multiple intake (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc

Single intake (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc nc nc nc nc nc c nc c c nc c

Multiple intake (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c nc c

Only Ventilation / Actuated ramps c c c c nc c c c c c c c c c c c nc nc nc c c nc c c c c c c c c

Only Ventilation / Non actuated ramps c c c c nc c c c c c c c c c c c nc nc nc c c nc c c c c c c c c

Only Ventilation + Cooling / Actuated ramps c c c c nc c c c c c c c c c c c nc nc nc c c nc c c nc c c c c c

Only Ventilation + Cooling / Non actuated ramps c c c c nc c c c c c c c c c c c nc nc nc c c nc c c nc c c c c c

Ejectors (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c

Ventilators (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c

External source (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c

Ejectors (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c nc c nc nc c c c c c c nc nc nc

Ventilators (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c nc c nc nc c c c c c c nc nc nc

External source (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c nc c nc nc c c c c c c nc nc nc

MPU heat exchanger within the coffin - Ambient Air c c c nc nc c c c c c c c c nc c nc nc nc nc c c nc c c c nc c c nc nc c c c c c c c nc nc nc

MPU heat exchanger out of the coffin c c c nc nc c c c c c c c c nc c nc nc nc nc c c nc c c c nc c c nc nc c c c c c c c nc nc nc

MPU heat exchanger within the coffin - Cabin Air

Shared with MPU c c c nc nc c c c c c c c c nc c nc nc nc nc c c nc c c c nc c c nc nc c c c c c c c nc nc nc c c

Dedicated

MPU Supply c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c c c c nc nc nc c c c

Independet nc

With regulation (variable multiplication) nc

Without regulation (fixed multiply) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c c c c nc nc nc c c c c

115 VFG (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c c c c nc nc nc c c c c c

270 VDC (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c c c c nc nc nc c c c c c

115 CFG (Diesel Eng.) c c c nc nc c c c c c c c c nc c nc nc nc nc c nc nc c c c nc c c nc nc c c c c c c c nc nc nc c c c c c

230 VFG (APU) nc nc nc c nc c nc nc nc nc nc nc nc c nc c nc nc nc nc c nc c c nc c nc nc c c c c c c nc nc nc c c c nc nc nc nc nc

115 V (Hi-RAT) nc nc nc nc c nc nc nc nc nc nc nc nc nc nc nc c c c nc nc c nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc nc

B2a

- Int

alla

tion

/ Pos

ition

A4 -

Exha

ust

B2b

- Int

alla

tion

/ Cof

fin

Conf

igur

atio

n

B5a

- Air

Supp

ly (O

nly

Dies

el E

ng. &

APU

)

A7 - Cooling (Only Diesel Eng. Heat

Exchangers)

B2b - Intallation / Coffin Configuration

B0 - Mission Power Gen Selection

B1 - Fuel Architecture / Integration

(APU & Diesel Eng.)

B0 -

Miss

ion

Pow

er G

en

Sele

ctio

n

B1 -

Fuel

Arc

hite

ctur

e /

Inte

grat

ion

(APU

& D

iese

l

Eng.

)

B2a - Intallation / Position

INCOMPATIBILITY MATRIX

A330 AWACS Mission Power Generation

Last update: 28th November 2016

A8 - Cooling electrical generator

A9a - Gear box / Supply

A9b - Gear box / Regulation

B11 - Generators

A4 - Exhaust

B5a - Air Supply (Only Diesel Eng. &

APU)

B5b - MPU Compartment Ventilation /

Intake (Only Diesel Eng. & APU)

B5c - MPU Compartment Ventilation /

Ramps (Only Diesel Eng. & APU)

B6a - Ventil lation on ground / Diesel

Engine

B6b - Ventil lation on ground / APU

B5b

- MPU

Com

part

men

t

Vent

ilatio

n / I

ntak

e (O

nly

Dies

el E

ng. &

APU

)

B5c

- MPU

Com

part

men

t

Vent

ilatio

n / R

amps

(Onl

y

Dies

el E

ng. &

APU

)

A7 -

Cool

ing

(Onl

y Di

esel

Eng.

Hea

t Exc

hang

ers)

B11

- Gen

erat

ors

A9b

- Gea

r box

/ Re

gula

tion

A9a

- Gea

r box

/ Su

pply

A8 -

Cool

ing

elec

tric

al

gene

rato

r

B6a

- Ven

tilla

tion

on

grou

nd /

Dies

el E

ngin

e

B6b

- Ven

tilla

tion

on

grou

nd /

APU

iDG sii and : -Gear Box interface requirements met-Gear box not including RPM regulation

ID

Requ

irem

ent

Stat

us

Rq T

arge

t

Req

Type

B0 -

Miss

ion

Pow

er G

en S

elec

tion

B1 -

Fuel

Arc

hite

ctur

e / I

nteg

ratio

n (A

PU &

Die

sel

Eng.

)

B2a

- Int

alla

tion

/ Pos

ition

B2b

- Int

alla

tion

/ Cof

fin C

onfig

urat

ion

A4 -

Exha

ust

B5a

- Air

Supp

ly (O

nly

Dies

el E

ng. &

APU

)

B5b

- MPU

Com

part

men

t Ven

tilat

ion

/ Int

ake

(Onl

y Di

esel

Eng

. & A

PU)

B5c -

MPU

Com

part

men

t Ven

tilat

ion

/ Ram

ps

(Onl

y Di

esel

Eng

. & A

PU)

B6a

- Ven

tilla

tion

on g

roun

d

B6b

A7 -

Cool

ing

(Onl

y Di

esel

Eng

. Hea

t Exc

hang

ers)

A8 -

Cool

ing

elec

trica

l gen

erat

or

A9a

- Gea

r box

/ Su

pply

A9b

- Gea

r box

/ Re

gula

tion

B11

- Gen

erat

ors

Are the chosen

solution compliant

with the rqt ?

TLARD 24.1-3 Nominal Electrical Power

350kW@270VDC

3 kW@230VDC

50kW@28 VDCx x x YES

TLARD 24.1-5 Electrical Power with Single Failure 260kW@270VDC

40kW@28 VDCMPU generator failure x x x YES

TLARD 1.2-3 Civil Certification with EASA. CS 25

Certification Bases not

existing for reciprocating

engines APUx x x x x x x x x x x x x x x YES

TLARD 2.5-1Mission System powered ON at altitudes

from 7km to 12km above MSL only

20000ft up to

40000 ft x x YES

TLARD 49.1-2Each Power Generator Unit shall be

suitable for use on the ground and in fl ight

50 Kw

ISA +40

To need to clarify the

meaning of “operation on

ground”x x YES

TLARD 2.6-2

Average internal noise level with Mission

Systems in OFF at all speeds (power

generation is included in Mission Systems)

<80 dB x x x x YES

TLARD 49.6-2

Controls for Power Generator Unit starting,

shutdown, fire detection and fire

extinguishing (if required) shall be

provided in the cockpit/cabin.

It is assumed that EASA will

require Safety related

controls and indicating in

cockpit

x x x x x x x x x x x x x x YES

Key Trade-off contributing to the requirement & Chosen solution

Configuration Check Sheet

SBCE- The Results

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation10

Better master cost

and Schedule

Adaptable to requirement evolutions

Fosterinnovation

IncreaseLearning

Capitalize knowledge for future project

Organize the fuzzy front-end part of a complex project

Global optimum

SBCE - Lessons Learnt and VoC

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation11

Airbus Future Challenges

October 25th, 2017 Airbus DS Lean Journey to Acceletare Innovation12

Thank you