DREAMS TODAY TECHNOLOGY TOMORROW - Value …€¦ · DREAMS TODAY TECHNOLOGY TOMORROW CSVA Annual...
Transcript of DREAMS TODAY TECHNOLOGY TOMORROW - Value …€¦ · DREAMS TODAY TECHNOLOGY TOMORROW CSVA Annual...
DREAMS TODAY TECHNOLOGY TOMORROW
CSVA Annual Conference, Montréal
Keppel N Bharath
Senior Manager / Fellow PW800 Turbofan Program
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DELIVERING MORE WITH LESS
-The future is linked with us bringing the nations together to solve the Risks that have been identified
-The Global Environment for business is more competitive and challenging than ever
-Our PEOPLE will transform our industries with game- changing products and technologies
-Let us embrace change and engage one another to drive the next generation of innovation
-Whatever you do must cost less to produce than today
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UNITED TECHNOLOGIES
CORPORATION
Export Classification: No technical data
Commercial Engines
Military Engines
Aeropower
Aircraft Systems
Power, Controls &
Sensing Systems
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A MAJOR CANADIAN EMPLOYER
Lethbridge
Mississauga
Halifax
Longueuil
Engine development and production
Corporate headquarters Engine development,
production and aftermarket
Engine production
Component manufacturing
Mirabel
Engine production Assembly & test
Flight testing
Ottawa
Manufacturing and R&D facilities
across Canada
Altitude test facility with the National
Research Council
Maintenance, Repair and Overhaul
Thompson
GLACIER
cold weather
testing and
research facility
Export Classification: No technical data
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Hawker Beechcraft T-6A JPATS
Embraer Super Tucano EMB-314
P&WC KEY BUSINESS SEGMENTS
Corporate
Military
Regional Civil helicopters
Aftermarket
General aviation
Dassault F7X
ATR 72 AgustaWestland AW139 Eurocopter EC135
Hawker Beechcraft King Air 350
Bombardier Q400
Embraer Phenom100
Maintenance, Repair and Overhaul
Customer First Centre
Cessna Sovereign
Export Classification: No technical data
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P&WC PRODUCT MANDATE
Auxiliary power units
PT6A
PW500
PW300
JT15D PW100
PW150
PW200
PT6T/B
PT6C
PW600
Turboprops 600 – 6,500 shp
PW800
Turboshafts 600 – 2,200 shp
Turbofans 900 – 20,000 lbf
PW900
Over 70,000 engines produced
10,000 Operators in 198 Countries
Export Classification: No technical data
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LEADING R&D INVESTOR
In Canadian aerospace
Over 1,400 engineering staff in Canada
$ CAD
Millions
Export Classification: No technical data
423 466 472 481
457 454
378 385
473 527
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
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70+ ENGINES CERTIFIED SINCE 1994
0
1994 1996 1998 2000 2002 2004 2006 2008 2010
Citation Excel PW545A
Bell 412
PT6T-3B
Eurocopter EC135
PW206B
Casa 295
PW127G
Bombardier Q400
PW150A
MD Explorer
PW207E
Dassault 2000EX
PW308C
HBC Hawker 4000
PW308A
Cessna XLS
PW545B
Dassault Falcon 7X
PW307A
Embraer Phenom 100
PW617F
Cessna Mustang
PW615F
10
20
30
40
50
60
70
HBC King Air 200GT
PT6A-52
Embraer Phenom 300
PW535E
Bell 429
PW207D
B747-8
PW901C
Export Classification: No technical data
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THE CONSTRAINTS ARE CHANGING
Globalization
Environment Costs
Workforce /
Manpower
Problem Statement: How do we do more with less with these constraints
Capacity
Export Classification: No technical data
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Copyright © Pratt&Whitney
Canada Cie.
VALUE METHODOLOGY OVERVIEW
ACE Operations Transformation - ‘03 3P, VSM, etc
ACE Launch - ‘98-’99
First Cells Achieve Silver Supply Chain Excellence - ‘00 ACE Tool Box, Master Methods,VSM
First Cell Achieves Gold - ‘02
KAIZEN - ‘93-’96
Q + ‘86-’90 Value Engineering - ‘96
Quality Function Deployment - ‘98
Risk Assessment - ‘01
Direct Value Measurement - ‘99
Product Function Specification - ‘98
Parametric Paired Comparison - ‘97
Parametric Cost Estimation - ‘00
Lean Engineering - ‘03 Project Mngt, EVM, etc.
Export Classification: No technical data
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CHALLENGE THE STATUS QUO
VISION STATEMENT :
Reduce the Build, Test & Pack time from 8 shifts to 8 hours MAURICE WEINBERG Exec offsite Sept 2002
Current lead-time T/Fan Proposed Lead Time PW600
Engine build 45 hrs 4.0 hrs
Engine dress 2.5 hrs 0.5hrs
Testing 6.5 hrs 2.0 hrs
Undress 2 hr 0.5hrs
Packaging 4 hr 1.0hrs
TOTAL 60.0 hrs 8.0hrs
GOAL:
1 Engine every 8 hours
Export Classification: No technical data
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THE PW600 VISION
Engine lead-time from 8 shifts to 8 hours
Export Classification: No technical data
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TECHNOLOGY FUNNEL
Needs structured methodology to deliver the identified value
Increasing TRL, reducing risk
Export Classification: No technical data
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Research &
Technology
Systems
Turbo
ECN
Dev’t Module
s -
Dis
cip
line &
Resourc
es M
anagem
ent
Engineering Services
Product Data and Business Processes
Business &
Finance
Human
Resources
Technical &
Quality
Support
Functions
New Product
Introduction
Support to
Operations
Product
Management
Product
of choice Research &
Technology
ENGINEERING STRUCTURE
Focused project management for technology development
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TECHNOLOGY MANAGEMENT PROCESS
1. Product Technology
Strategy Definition
3. Technology Projects
Selection and Prioritization
4. Technology
Projects Management
5. Technology
Transfer to Programs
2. Idea Incubation
Process
TRL 1-5
TRL 6
TRL 0
Technology
Insertion (Programs)
TRL 6-9
1. Align Research activities with
Strategic priorities
2. Generate and incubate innovative
ideas
3. Optimize R&D Investment by
proper project selection &
prioritization
4. Minimize time and cost from idea
generation to entry to service
5. Introduce mature technologies to
engine program to minimize
development risks and maximize
competitive advantage
6. Leverage global funding and talent
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Concept initiation Concept optimization Preliminary design Detail design
1
2
3
4
5
6
TRL
IPD Phase:
Passport: 0 1 2
Technology Readiness Level Progression
Concept initiation Concept optimization Preliminary design Detail design
1
2
3
4
5
6
TRL
IPD Phase:
Passport: 0 1 2
Technology Readiness Level Progression
Concept initiation Concept optimization Preliminary design Detail design
1
2
3
4
5
6
TRL
IPD Phase:
Passport: 0 1 2
Technology Readiness Level Progression
Technology
Development
Plans
)
Technology
Development
Plans
)
Product
Opportunities
Product
Opportunities
Required
Validation
Required
Validation
Technology
Development
Planning
Technology
Development
Planning
Technology Plan
Technology
Development
Planning
Technology
Development
Planning
Technology Plan
Technology
Portfolio
Technology
Portfolio
9
8
7
6
5
4
3
2
1
TRL
Levels
In service
Qualification/
certification
Flight test
System-level
validation
Rig/core
(expanded design
space)
Rig test (minimaldesign space)Rig test (minimaldesign space)
Proof-of-concept
Technology
application
Basic principles
System
Technology
Requirements
System
Technology
Requirements
Technology 1
Technology 2
Technology 3
Technology 4
..............
Technology
Prioritization
Technology
Prioritization
Technology 1
Technology 2
Technology 3
Technology 4
..............
Technology
Prioritization
Technology
Prioritization
Customer & Market
Requirements
Customer & Market
Requirements
Product & Service Plan
Thru
st
Year
Customer & Market
Requirements
Customer & Market
Requirements
Product & Service Plan
Thru
st
Year
Advanced Design
Studies
Advanced Design
StudiesAdvanced Design
Studies
Advanced Design
Studies
Validated
Technologies
Validated
Technologies
Technology
Insertion
Technology
InsertionTechnology
Insertion
Technology
Insertion
Technology
Validation
Technology
ValidationTechnology
Validation
Technology
Validation
INNOVATION IS KEY….MADE ON EARTH Develop technologies worldwide in Parallel Globalization
Export Classification: No technical data
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Copyright © Pratt&Whitney
Canada Cie.
INPUTS • Risk Assessment
• Risk Exposure
• Risk Cube
• Past Risk Mitigation Experience
• Alternative Plan Possibilities
OUTPUTS • Risk Mitigation Plan
• Waterfall Chart
• Risk Reduction Monitoring
(%)
RISK ASSESSMENT IN MITIGATION OUT
Export Classification: No technical data
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WHEN & WITH WHOM TO INVEST
Low High
Degree of Competitive Advantage
Develop
Partner
Procure
Commercial available
to all competitors but
required to maintain
competitive parity
Commercially
available but unique
application creates
competitive advantage
Technology creating
unique competitive
advantage
Export Classification: No technical data
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WHERE TO INVEST
For technology development, the value equation requires an
additional term
Success probability is required due to the high degree of
uncertainty around innovation
Value = Potential Benefit x Probability of Success
Non Recurring Engineering Investment
Export Classification: No technical data
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ENVIRONMENTAL FOOTPRINT Develop a Total Environmental Footprint Model
CO, VOC, NOx, smoke, ICAO
Regulations, Landing fee
surcharges, health effects
Optimize Manufacture logistics based on Greenhouse gases
And KW/ KG of energy required
ATR 72
Environment
Export Classification: No technical data
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Copyright © Pratt&Whitney
Canada Cie.
The long Road to PW600 Value
Event No
Pro
du
ct
Event DescriptionEvent
Type
VE-1999-147 GA Engine Market Analysis DVM
VE-1999-142 GA Engine RGB FA
VE-2003-347 PW610 Manufacturing Review QFD
VE-2003-329 PW610 Production Plan QFD
VE-2003-343 PW615 Key characteristics definition QFD
VE-2002-288 GA Market Values for GA QFD
VE-2001-261 PW610 PW610 QFD Session QFD
VE-2000-220 PW6xx New concept QFD
VE-2002-305 PW610 Risk Assessment - Program Risk
VE-2002-313 PW610 Risk Assessment Risk
VE-2003-363 PW610 Risk on Thermal Mgmt Risk
VE-2002-314 PW615 Risk Assessment Risk
VE-2002-304 PW6xx Combustor / fuel manifold Risk
VE-2002-279 PW6xx Riak Assessment Review / Update Risk
VE-2002-292 PW6xx Low Cost EEC: Risk Assessment Risk
VE-1999-152 GA Gas Turbine Blade TRIZ
VE-1999-164 GA LP Shaft TRIZ
VE-2000-179 GA Total Engine VE
VE-2000-196 GA TP Assy & Test Process VE
VE-2001-243 PW610 Function/Cost analysis VE
VE-2002-325 PW615 Monocase VE
VE-2003-366 PW615 VE with suppliers TOP 32 parts VE
VE-2001-254 PW6xx Bearing Housing-Cost red KFW VE
VE-2001-260 PW6xx PW625 TEC VE session VE
VE-2002-281 PW6xx VE Cost reduction - AGB Oil Tank VE
VE-2000-222 PW6xx Cost and weight/ LPC, HPC VE
VE-2000-213 PW6xx Cost / Producibility VE
• 50 % Parts count reduction
• 5 Rotating stages Vs. 8
• 3-5% better performance
• 10% better thrust to weight
• Adapted for volume production
• Easier maintenance
• Competitive durability
• Proven technology
• Uncompromised reliability
22 PWC Proprietary Data
CGP CONTROLLED
NOVEL MANUFACTURING TECHNOLOGY
Status
Moving line is activated when 100% of components released to floor.
Build time for an engine video taped at 3:58
Incremental improvements required to go to 3:30
Next steps
Copy line to all production facilities
Overhaul Challenge
Reverse line flow at the overhaul shop to achieve a 7 day Turn Around Time for field
engines
GOAL: 1 ENGINE EVERY 8 HOURS
Assembly Moving Line 1 month inventory 27 Producers for full Engine Forward Stocking Location
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Copyright ©
Pratt&Whitney Canada
Cie.
Conclusions
Whenever great minds get together to solve issues great things happen
The World is Flat. Use that fact to our advantage
If given the opportunity , YOUR PEOPLE can transform the Industry with
game changing Technologies and Products
Let us embrace change and engage one another to drive the next
generation of innovation
PWC Proprietary Data
CGP CONTROLLED