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Innovation and safety: A contradiction or 2 sides of the same coin? Jan Verbeek Herry Klumper Kees Vernooij Ron van Baaren Delft – March 5th 2013
SAFE presentation - innovation and safety
2013 © ADSE B.V. 2 SAFE presentation - innovation and safety
Aircraft Development and System Engineering
Founded in 1996 by former Fokker Aircraft engineering managers
ADSE is an independent “make it work” consulting and engineering company with 70 employees in Nld, 7 in Switzerland
&
Focused on complex systems integration • ADSE has been recognized by EASA as Qualified Entity • ADSE holds an EASA.21J.481 Design Organization Approval
Aerospace Mobility Defense
High Tech Equipment
Offshore & Marine
Special Vehicles
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Our customers – their questions
Operators, MRO
SystemIntegrators
Authorities Suppliers
ADSEMake it work
Risksharing partners
Life cycle cost
Design for Assembly
ReliabilityAvailability
Safety Management
Regulations
Supply Chain Management
Oversight
Performance guarantees
Design for RAMS
Certification
Signatory delegation
Regulatory development
Maintenance Optimisation
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Our World Aerospace – example projects
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Introduction
• Air Transport has shown sustained growth over the years
• Enabled by performance improvements, year over year • New technologies • Business & process innovations
• Further growth needs further improvements
• On the other hand the industry is blamed for inertia and bureaucracy • Tedious certification procedures • Enormous development cost • Long time to market
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Our (end) customers expect
• Improvements of all aspects
• Proven from day 1
• So we need to innovate in a controlled manner! • As fast as possible • At acceptable cost
Safety
Functionality Efficiency
Availability
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A typical product life cycle
20-30 years
Influence on
Design
Production
Operation
Recycling / Disposal
Requirements R(esearch) &iDeas
Production
Product
Operation
Modification
Retirement
Development:
Maintenance
10-20 years 5-6 yrs 30-40 years
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The current business case
Source: Zabka, W. The judgement and evaluation of long-term investments Demonstrated by means of a civil aircraft program - Agard Conference Proceedings no. 424, September 1987
TOP DOWN TARGET COSTING
Other cost(Budgets)
NRC targets
RC targets
Customer
BOTTOM UP COST ESTIMATE
Other cost NRC RC
Supplier
Negotiation
• From operator to OEM • Sales price & training cost • Operating & MRO cost
• From OEM to suppliers
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Maintenance Part-145
Design CS-23 / 25
OEM AUTHORITY USER
Review board
Airworthiness Records
User JAR/EU-OPS
Maintenance training Part-147
Certifying staff Part-66
Accidents Incidents
MOA
AD’s Mods
CA Requirements Part-M
Certification & Production
Continuing Airworthiness
MME
Production Part-21 G
Certification Part-21 DOA
POA
Production Incidents
Maintenance Incidents
Current certification standards
EASA Regulations
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The certification process
Requirements development
Policy
Development
Design, Built, modification, maintenance
en certification
Use/Operation
Incidents/ Failures
Incident/Failure analysis
System monitoring
and analysis • Ongevallen • Incidenten • Performance
indicators
• Gecertificeerd product
• Procedures • dossier
• aanbevelingen
• doelstelling
• aanbevelingen
• richtlijnen
• statistieken
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Design process
Certification process
Requirements Policy development
Oversight process
Design Use/ Operation
Safety Analysis Safety
monitoring
Built
Verification & Validation Verification
Safety Management System
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Aircraft design
Sub system design
System design
Module design
Sub system design Sub system design Sub system design
Parts design
Material
Module design
Parts design
Material
Module design
Parts design
Material
Module design
Parts design
Material C
ertif
icat
ion
Spe
cific
atio
n
Design & Certification
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Introducing new technologies
Has effects on: • Development • Certification • Assembly • The supply chain • Operators • Maintainers (repair)
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Composite: Showing Compliance
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Boeing 787 repair development
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Real world - severe - damage
• Not (yet) in Structural Repair Manual? • What to do?
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Real world - damage?
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Safety culture aspects
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The challenges ahead
SAFE presentation - innovation and safety
Influence on
Design
Production
Operation
Recycling / Disposal
Requirements R(esearch) &iDeas
Production
Product
Operation
Modification
Retirement
Development:
Maintenance
10-20 years 5-6 yrs 30-40 years 20-30 years
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Lessons learned: Production Innovations
Hrs & cost
Product development & Industrialisation
Learning curve & ramp up Hrs & cost
Deliveries
Time
Time
Shortening lead times further - First article ‘right first time’ - Faster learning curve and ramp up
New product development Expected hrs & cost for engineering
New product development Expected hrs & cost for production
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Leverage via Concurrent Engineering
Development Operation
& Support R&D
Many iterations Avoid iterations
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Innovate certification
• Certification requirements • The number of requirements has grown considerable
• Have some become outdated / irrelevant? • Is there enough research done to guarantee effectiveness and efficiency?
• Is there enough scientific research done to prepare new requirements for new technologies?
• How are suppliers involved? Do 1st, 2nd and 3rd tiers fully understand the process and the requirements?
• Is there a better, more efficient, way of showing compliance? • Analysis (more?), Testing (less? or dual use of development testing?) • Reporting (is there a better way - rethink old practices?)
• Can we incorporate certification aspects more during R&D • Involve authorities and operators/maintainers during R&D • Use of more demonstrators (like EU Clean Sky approach) • Seek more synergy with development & qualification of series
production standards • Apply more Lean / 6 sigma thinking during R&D
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Innovate deployment
• The minimum (traditional) deployment preparation is not enough • For the Operators, Maintainers: training (awareness, skills,
procedures) • For the OEM’s and main suppliers: operators and maintainers
minimal involvement during R&D and development activities
• New technology introduction needs more awareness and focus • To identify “unknown unknowns” early on (pref. during R&D) • To develop and plan comprehensive and realistic deployment
schemes
Safety
Functionality Efficiency
Availability
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Innovate deployment
• Organizations do not learn, only people do
• So, a better understanding is needed in the industry: • Who are direct or indirect affected by new technology? • How do people, teams and supply chains learn?
• Basic individual skills • Hands on experience build up of individuals, teams (and supply chains) • Awareness for required changes of culture/tribal knowledge
• How do we spread know how and know why and lessons learned to big groups of people (across the globe)
• How do we assure and control this – certify this?
• And translate this into more effective deployment schemes • Leading to faster Time to Market • Spend a little more early and pay far less for problems later
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Concluding
• Innovation and safety are “part of the same coin”
• They should be treated in integration instead of in competition
• Innovations of Certification and Prepare for Deployment processes need more attention
• Certification can benefit from a more integrated approach in R&D
and from more R&D on airworthiness requirements and certification methods and subsequent process innovation
• Operators and Maintainers can benefit from lessons learned in Design for Production & Industrialization to prevent possible “loss of learning” in case of new technology introduction
SAFE presentation - innovation and safety
