11102020 Sophie BETTI Florent DUPUY Manufacturing Engineering Presentation
11/10/2020 Sophie BETTI Florent DUPUY Manufacturing Engineering Presentation BLMLII – June 2009
Manuf Engineering - Summary I. Manuf Engineering generalities II. The 3 activities III. Conceiver Manuf-Engineer IV. Serial Manuf-Engineer © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. V. Technical Support VI. The Digital Mock-Up M. E. Movie 2
Manuf Engineering Manuf architect Interface Role Procurements/Logistics Design Office Accounts Dpt © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Manuf Engineering Tools D. O. & Methods Work Study Agent Workshop & Quality 3
Manuf Engineering From the product conception phase, the Manuf Engineering PREpare the Workshop realisation job taking in account the productivity objectives : quality, costs, delays & security. The Manuf Engineering Imagines and Creates © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. the Operative Methods and the Technical Instructions used by the Workshop to Manufacture and Assemble the aircraft components. 4
Manuf Engineering The Manuf Engineering in the industrial Process: Conceiver Manuf-Enginner 10% Specify © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. D. O. Serial Manuf Engineer 60% Define Prepare Launch Definition Dossier Workshop Technical Support 30% Manufacture Assemble As Prepared Work Order Certify Deliver Quality P. Q. R. A. I. R. 5
Manuf Engineering Each specific profession has: - 1 process described in the Airbus cartography AOPM © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. - 1 skills and Airbus knowledges list Optimize Skills & « borne métier » - 1 documentary referential @bcd, “borne métier” 6
Specific profession details: © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Conceiver Manuf-Engineer Serial Manuf-Engineer Technical Support Elaborates the industrialization dossiers AND Calculates Proves and validates the « as planned » and the « as prepared » AND Prepares the work generated by the manufacturing problems Manuf-Engineer’s Major roles Contributes to the product definition and to the realisation and check means And Evaluates the costs and the industrialization cycles. Information Support Pre-project Pre-enquiry Definition Dossier Work order Products and physical means Work place In operational team with the A/C D. O. and the tooling D. O. Manuf-Engineer office Workshop Results Required Skills - Industrial sharing plan (manufacturing plan) - Definition dossier -Manufacturing techniques -Files management As prepared -Validated « as prepared » -Specific « troubles » dossier -Configuration management -Manufacturing management (GPAO) 7
Manuf Engineering Each specific profession is supported by the « Central Manuf -engineering » which is in addition in charge of: - projects axis - harmonization © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. - between FAL’s - within Airbus France - within d’Airbus - users job support - surveillance - strategy 8
Manuf Engineering The manuf-engineering in the industrial PRE-Project PRODUCTION CONCEPTION PRODUCTION PREPARATION MANUFACTURING TECHNICAL SUPPORT Project Start © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. M 1 Basic A/C definition Concept M 3 Program Pre-Launch M 5 M 2 M 0 M 4 Idea of the product Requirementat Production Concept At A/C basic level Decision to conceive Feasability Phase Program Launch M 9 M 7 M 6 Marketing Authorization Conception Definition Phase Start of FAL M 8 First chip First Flight Entry Into Service M 11 M 10 First A/C Power. ON M 13 M 12 Certification M 14 End of development Serial Phase Development Phase 9
Conceiver Manuf-Engineer Ressources A/C Definition (buildings, machines, tools, menpower…. . ) © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. 3 D digital mock-up Macro ‘work order’ Assembly Process Virtual Validation Definition & Validation 10
Conceiver Manuf-Engineer – A/C Definition © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. The digital mock-up is the result of 3 D numeric models (parts) assembly. 11
Conceiver Manuf-Engineer - DMU © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. The Manufacturing mock-up review: check the mountability of the elements of definition: a/c + tools + buildings Numeric simulation : virtual risks analysis 12
Conceiver Manuf-Engineer Virtual Validation © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. The simulation allows the evaluation of complex systems behaviour and to guarantee the elements integration 13
Serial Manuf-engineer The 6 main steps for the serial manuf engineer Definition Analysis Process Elaboration © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Risks Analysis Definition Lock & Technical writing Delta 2: Conf Manag Process Validation 14
Serial Manuf-engineer : Definition Analyse © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. The definition or « plan » is composed of: - the E. C. N. : Engineering Change Note - the B. O. M. Bill of Material - 2 D drawings - 3 D Digital mock-up The definition is analysed and, if a defect is detected the manuf-engineer indicates it through a DQN (Design Query Note). Then the definition is changed into the « as prepared view » : 1 PLAN = 1 work order 15
Serial Manuf-engineer : process elaboration Imaginer ou adapter un processus d’assemblage - Mode opératoire = Liste des opérations à réaliser (successives ou en //) avec le temps au rang 100 (t 100), la compétence atelier, … - Nomenclature = Liste des éléments utiles à l’assemblage - éléments avionables : pièces, produits qualifiés, sous-ensemble, kit… © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. - éléments non avionables : produits de nettoyage, prédécoupés ( « pochoirs » de peinture) … - Expression de besoin fonctionnel d’outillage - Documents complémentaires (fiche d’instruction, Guide et relevés, procédés utilisés…) Préparer l’analyse des risques 16
Serial Manuf-engineer : analyse de risques Avec un représentant des métiers : © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. üAtelier üQualité üSupport technique üErgonome üAgent d’Etude du Travail üBureau d’etude Outillage üLogistique… Dérouler le mode opératoire et lister les risques (humain et produit) et défaillances / 5 M Chiffrer la criticité de chaque risque : üGravité üOccurrence üDétectabilité si >100 mise en place d’ 1 ou + DAQ 17
Serial Manuf-engineer : autres activités • Bloquer la définition : - empêche le BE de modifier le dossier de définition concerné - si modif impérative le BE est obligé de contacter le préparateur et « négocie » le rang d’application. • Rédaction technique © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. une FI = « lire pour faire » Structure harmonisée : sommaire, enchaînement des opérations, état final attendu, position texte / illustration, lexique … 18
Serial Manuf-engineer : Gestion de config: Delta 2 Gestion de configuration = cohérence entre spec client et produit livré au client Le préparateur est concerné par le « delta 2 » qui est l’écart entre les phases définir et préparer, une fois sa définition bloquée. Spécifier Définir D 2 Préparer Lancer © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Fabriquer Assembler Attester Livrer Outils: Maeva et Delta 2 Eq (SA + LR) Mega 2 et Mega 2 Eq (A 380 + A 400 M) 19
Serial Manuf-engineer : validation de processus Valider les processus opératoires - L’enchaînement des opérations La faisabilité Les temps de réalisation Les outillages utilisés et leurs fonctionnalités etc, etc…. lors des premières applications série en Atelier © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. par la méthode dite des 5 M. Liste des intervenants: 4 Atelier, Opérateur 4 Préparateur / Support technique (Pilote) 4 Support Qualité 4 Support Logistique 4 AET 4 Bureau Outillage Présence obligatoire 20
Serial Manuf-engineer : étapes du dossier de prépa Prépa. Ordo. Prépa. ou ST © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Atelier + Qual. + Prépa. Groupe de validation Création du dossier de préparation Processus à valider Lance l’OF Passage automatique du statut de la gamme en « processus en cours de validation » Mettre en œuvre le processus Processus en cours de validation Vérifier la FVP et la renseigner Examiner les résultats Valider le processus, sinon débattre des corrections à apporter Qualité Valider les outillages Prépa. Passer le statut de la gamme en « processus validé » Processus validé 21
Cascade du dossier de préparation PROGAMME © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. STATION FONCTION MONTAGE Validité OPERATION Gamme OPERATION Opératoire OPERATION Documents Outillages Processus PIECE EQUIPEMENT - FIN CMS ARTICLES ou OBJET CONFIGURATION 22
Technical Support de proximité situé à l’atelier Il met au point le produit, le processus, les moyens et les interfaces lors des premières utilisations et applications à l’atelier Validation de Processus © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Valider un processus c’est: - L’enchaînement des opérations - La faisabilité - Les temps de réalisation - Les outillages utilisés et leurs fonctionnalités 23
Technical Support Il réagit aux aléas techniques (litiges, dérogations, OT de parachèvements…). Aléas de production Conforme à la définition? Oui Litige / DQN © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Non Anomalie « démontable » Oui AM (Qualité) Non (ex: perçage trop grand) AM + Dérogation (soumis à accord BE) 24
Serial Manuf-engineer : in brief Definition Dossier Tool functional Spec New one or evolution of one Imagine or adapt the process Macro W. O. PAT © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Production Process validated Risks & defects analysis Up & Downs yes no Process Validation ? Update as prepared view 25
© AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. DMU – Digital Mock-up Digital Mock-Up Real A/C: 26
© AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. DMU – Digital Mock-up 3 D instruction sheet: 27
DMU – Digital Mock-up © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Examples of Instruction Sheets in 3 D animated / Hambourg A 380: A 350 Macro Assembly: 28
Correspondance cascade BE-PROD Cascade Bureau Etude F 531 10000 Cascade Production EC PROGA 340 Tronçon 11 supérieur F 531 10018 000 TRD STAT FQD 590 Liaison plancher /Casquette FM F 53 B 100425 Poste de montage RF Sol Validités F 531 10066 000 Plan Sol de montage OPE Liaison C 1/Plancher © AIRBUS FRANCE S. All rights reserved. Confidential and proprietary document. Gamme de montage F 531. 10066. 000 Gamme de fabrication P/N F 531 10433 200 Gousset FIN PQ PIE EQ CMS 12 MJ 1 PQ 10050 -00 Equipement Mastic F 531. 10433. 200. 00 F-12 MJ 1 4988987847 CMSE 2014124708 634705300 Matière ASNA 30128600001 Tôle mince 634705300 PIE: élément magasinable ( S/Ens ou PE ) non affecté à un avion 29
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