HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT M. GREILLER (Eurocopter) VI VACE For um 1, War w i c k UK, 20-21 Sept ember 2005 Page: 2 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Table of contents HELICOPTER INDUSTRY PARTICULARITIES Multiple customers and missions Market characteristics Heavy development DEVELOPMENT PROCESS DESCRIPTION General development process Pre-Design process USE CASE DESCRIPTION AS-IS pre-design process TO-BE pre-design process Benefits SCENARIOS Mastering uncertainty General architecture Life Cycle Cost Visualisation & selection ROADMAP W h y
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A c t i o n s Photos EUROCOPTER Page: 3 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 HELICOPTER INDUSTRY PARTICULARITIES Commercial companies offering regular flights (Off-shore, commuters) Customers : Charter or private owners Military or public customers Multiple customers and missions Search and Rescue Missions : Off-shore or commuter Military missions Photos EUROCOPTER Page: 4 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Very small series Many versions for the same type of helicopter Low self financing capacity Due to the small series, the recurrent costs and the sale prices cant be reduced. Fewer major national programs Decrease of great National contracts (usually military ones) Market characteristics HELICOPTER INDUSTRY PARTICULARITIES Photos EUROCOPTER Page: 5 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Complex air wake generated by the main rotor Behavior simulation difficulties Numerous modifications during the development phase due to: - Vibrations - Flight qualities - Icing - Wake interactions Parts generally reworked : - Position of the horizontal stabiliser - Anti-vibration devices - Air intakes - Upper cowlings Heavy development HELICOPTER INDUSTRY PARTICULARITIES Photos EUROCOPTER Page: 6 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 DEVELOPMENT PROCESS General development process Feasibility Pre-Development Development Industrialisation Service life support Pre-Design process Photos EUROCOPTER Page: 7 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Feasibility (Managed by Pre-project team) Actors: - Pre-project team, - Strategy, - Marketing and sales, - Finance. Results: - Top level requirements, - Technical feasibility document, - Business case. PRE-DESIGN PROCESS Pre-Development (Managed by Program team) Actors (those above and): -Project management -Technical specialists -Purchasers -Production Results: -Global aircraft and major sub- systems specification frozen. -Major interfaces frozen, -Major subcontractors chosen, -Risk management Plan, -Business case (complete) Page: 8 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 AS-IS Pre-design process USE CASE DESCRIPTION TO-BE Pre-design process Main risks and opportunities: Identification and assessment with a new process General architecture definition: - Customers requirements fulfillment - Simplification of the helicopter integration Costs evaluation : Assessment and optimization for a large panel of customers and/or mission Main risks and opportunities: Coming from experience of some specialists Costs evaluation : For each customer and/or mission General architecture definition: - New products derived from existing products. - Not complete pre-design phase, with high level of risks. Page: 9 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 USE CASE DESCRIPTION BENEFIT Spend more time and money during this first phase, in order to avoid a re- design later. HOW By using the 4 following scenarios 1. Mastering the uncertainty 2. General architecture 3. Life Cycle Cost 4. Visualisation and selection Page: 10 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 SCENARIO 1. Mastering uncertainty Scope : AS-IS Process TO-BE Process Data provided without assessment of their uncertainty. All values could be very lower or higher than the good data. Its mandatory to identify, categorise and quantify the main risks or opportunities before sending data Provide common methodology to express and assess the uncertainty of numerical data. Page: 11 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 - 1 - Identify and categorise all the types of risks - 2 - Map those Risks and trace their interdependencies. - 3 - Evaluate the existing probabilistic tool and make a selection. - 4 - Build a technical example - 5 - Perform sensitivity analysis of the example - 6 - Conclude with the benefit and the limits of themethod Scenario description : SCENARIO 1. Mastering uncertainty Page: 12 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Today reference Arithmetical sumof the elementary margins to ensure usual level of confidence for sub-parts Objective Save 20-30%of the standard margins Criteria - Metrics Identify and quantify R-O* Categorise R-O* and trace their interdependencies Aggregate elementary R-O* Service functions Criteria Margin to ensure usual level of confidence (90%) Perform sensitivity analysis Link back-up solutions * R-O = Risks or Opportunities SCENARIO 1. Mastering uncertainty Page: 13 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 This scenario is linked with WP3.3 through the following activities (Design to Decision Objectives) Analyse the state of art and propose adapted solutions Help to identify, categorise and map the generic risks and opportunities Evaluate the existing probabilistic tool and propose a selection Contributions Help for sensitivity analysis SCENARIO 1. Mastering uncertainty Page: 14 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Scope To formalise To make explicit The purpose of this scenario is The steps of the elaboration process for a global aircraft architecture and SCENARIO 2. General Architecture Photos EUROCOPTER Page: 15 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 TO-BE process : Pre-Project team Experience feed-back data base and tools Elaboration of balanced architectures for new helicopters 40% 60% Experience of involved people The definition Result of pre-project phase The technical specifications Context Hypothesis Choices Forgotten parameters AS-IS process SCENARIO 2. General Architecture Page: 16 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 - 1 -Collecting the Know-How of specialists - 2 - Collecting main justifications of general architecture - 3 - Formalising these informations for a further re-use - 4 -Developing of a tool to link the inter-connected subjects - 6 - Defining and formalising the criteria to assess an architecture. - 5 - Identifying the major topics or problematics, addressed by the general architecture process Scenario description SCENARIO 2. General Architecture Photos EUROCOPTER Page: 17 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Criteria Time to elaborate a new architecture Today reference About 1 year for experienced people Objective About 9 months Criteria - Metrics Service functions of the developed tool Identify and capitalise the Know-How of experienced people Make this Know-How usable for non-specialists Propose a formal model to elaborate an architecture Service functions SCENARIO 2. General Architecture Page: 18 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 This scenario is linked with WP3.3 through the following activities (Design to Decision Objectives) Define an adequate structure for the Know-How data-base Define the tools to link the inter- connected subjects Formalise the general architecture process Contributions SCENARIO 2. General Architecture Page: 19 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Scope Optimising the technical definition of a helicopter for : - Different customers - - Different requirements - - Opposite profiles - AS-IS &TO BE processes Market analysis for many customers, for only one definition Cost estimation based on the most critical mission Economical impact estimation for all the categories of customers Market analysis for all customers and all missions AS-IS TO-BE Technical choices (which involve a cost aspect) SCENARIO 3. Life Cycle Cost Page: 20 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 - 1 - Define the categories of customer - 2 - Adapt the sizing models of NLR and EC: find a common list of technical parameters - 3 - Develop the cost model - 4 - Perform sensitivity analysis on a limited number of parameters - 5 - Optimise helicopter definition for LCC of 1 customer first. - 6 - Define a criteria to combine LCC of multiple customers & missions - 7 - Optimise helicopter definition for this composite criteria Scenario description SCENARIO 3. Life Cycle Cost Page: 21 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Criteria Time to perform combined technical & market analysis Today reference 1 2 weeks (Models not complete or not connected) Objective 1 Day Criteria - Metrics Service functions of the developed tool Estimate the LCC of any technical definition for any customers profile Perform sensitivity analysis Optimise helicopter definition for LCC of 1 or multiple customers & missions Service functions SCENARIO 3. Life Cycle Cost Page: 22 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Adapt the sizing tool for cost calculations Connect the sizing tool with the cost model Define the multi- criteria optimisation method Contributions This scenario is linked with WP3.2 through the following activities (Multidisciplinary Design & Optimisation) Perform the sensitivity analysis SCENARIO 3. Life Cycle Cost Page: 23 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Scope : Visualisation of complete helicopter geometric models with: - Short access time - - Focusing only on interesting areas - - High precision - AS-IS &TO BE processes : The size of the models are too much important for a complete helicopter Models are too long to be visualised with usual CAD tools Capability to visualise any part of an helicopter in its context. Perform general architecture studies AS-IS TO-BE Only used for details studies, or with rough models for complete helicopters Visualisation of an entire digital mock-up SCENARIO 4. Visualisation and selection Page: 24 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Scenario description: - 1 - Evaluate existing visualisation tools - 2 - Define methodology to use those models - 3 - Select an existing tool or write an user specification for further tools. SCENARIO 4. Visualisation and selection Photos EUROCOPTER Page: 25 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 Criteria Time to visualise typical complete helicopter model Today reference About 1 hour Objective Few seconds Criteria - Metrics Service functions of the developed tool Visualise and animate models of complete helicopters, Refine selected areas up to elementary items Service functions Automatically simplify native models SCENARIO 4. Visualisation and selection Page: 26 2004 VIVACE Consortium Members. All rights reserved HELICOPTER PRE-DESIGN PROCESS IMPROVEMENT Warwick UK, 20 &21 September 2005 VIVACE Forum-1 ROADMAP First prototype release Solutions assessment & selection SEEMAGE software evaluation in progress. Requirements and specifications report DONE 4. Visualisation and selection First prototype release Solutions assessment & selection A helicopter Life Cycle Cost model was sent to NLR in order to integrate it into the NLR sizing tool SPEAR tool. Requirements and specifications report DONE 3. Life Cycle Cost First prototype release Solutions assessment & selection Assessment of a forecasted solution using INGENIUM software, in progress Requirements and specifications report DONE 2. General architecture First prototype release Solutions assessment & selection WP3.3 solutions assessment in progress. Requirements and specifications report DONE 1. Mastering the uncertainty M30 (Deliverable) M24 (Deliverable) M21 M12 (Deliverable) SCENARIO