Laboratory for Machine Tools and Production Engineering · Production Management A – Winter...

Production Management A – Winter Semester 2009/10

Technology Management 2 P. 0

Exercise 2

Production Management A

Exercise

Technology Management 2

Organisation:

Dipl.-Ing. Sebastian Nollau

Steinbachstr. 17Raum 235

Tel.: [email protected]

Laboratory for Machine Tools and Production Engineering

Chair of Production EngineeringProf. Dr.-Ing. Dipl.-Wirt. Ing. G. Schuh

Chair of Production ManagementProf. Dr.-Ing. A. Kampker



Exercise 2

Index:

Index Page 1

Aim of this exercise Page 2

Exercise Page 3

Introduction into the Technology Calendar

Case study: A380 engine components



Exercise 2

Aims of this exercise:

It is the goal of the second exercise of the technology management block of

lectures to deepen the insights from the lecture and to give an industrial

example for the roadmapping techniques.



Exercise 2

Page 3© WZL/Fraunhofer IPT

Structure

Introduction of the technology calendar1

Case study: A380 engine components2



Exercise 2


Why Technology Roadmapping?

Roadmaps…

� … help you to define your current situation and your target

� … support in finding the right way to your target

� … allow you to define interstations

� … offer flexibility in case of

– roadblocks

– changing targets

Technology Roadmapping…

� requires as-is-analysis and target definition

� shall support deriving the right way with intermediate results

� shall deliver operative support and flexibility in execution

Comments:



Exercise 2


Proceeding for creation of a technology calendar

technology identification

product analysis and generation of ideas

technology assignment

technology assessment

realisation planning

Comments:



Exercise 2


Product analysis and generation of ideas

� Identification of solution concepts

� Identification of approaches fromother branches

� List of approaches, e.g. regarding: - Change of design- Change of process chains- Change of materials

Documentation of results in PDS Generation of Ideas

Abstraction

Product Data

Sheet

As-Is data

Abstraction

Approaches

Legend: PDS = Product Data Sheets

PDS samples

Comments:



Exercise 2


Product analysis

� Analysis of technological data(geometries, tolerances, materials etc.)

� Functional analysis

� Load analysis

� Interface analysis

� Organisational framework

Generation of ideas

� Abstraction from the propertiesof the part

� Generation of solutions and of interdisciplinary approaches

� List of approaches for exampleto:- Change physical appearance- Change process- Change materials employed

GGestalt f reiheit

GGestalt f reiheit

GGGestalt f reiheit

BelastungBelastungBelastung

Schnit t stelleSchnit t stelleSchnit t stelle

µµµµ

Verschleiß

µµµµ

Verschleiß

µµµµµµµµ

Verschleiß

Oberf lächeOberf lächeOberf läche

ToleranzToleranzToleranz

Example: Mechanical load analysis for a gear wheel

Example product analysis

G

–

– Gegeben durch Schnittstellen

– Flanken

–

−

– Hohlrad

– Sonne

– Ritzel

– Anlagefläche:

– Parallelit ät der Anlagefl ächen

– Keine phosphortierten Scheiben

– Roughness

Rauheit

Durchmessertoleranz:

– Zahnflanken: Q 7

– Entgraten

– Montagehilfe

– Entgraten

– Maximum

– Minimum

– Zahnfußbiegespannung

–

− Durchmessertoleranz: − Roundness− Ma ß

G

GG

–

–

–

–

−

–

–

–

– Contact surface

– ät der Anlagefl ächen

– No phosphorized wheels

–

Roughness

Radius tolerance

– Q 7

–

–

–

–

–

–

–

−

−

−

GG

Parallelity of the contact surface

Interfaces

Flanks

Tooth geometry

Tooth type

Tooth base tension

Life cycle

Default position

Radius tolerance

Dimensional accuracy

Assembly aids

Deburring

Ring gear

Sun

Pinion

Tooth flanks

Deburring

Tolerance

Surface

Abrasion

Interface

Load

Freedom of design



Exercise 2


Analysis of information need:

Definition of search areas

� Monitoring Radar

– Structuring of relevant

search areas

– Enabling of the

aggregation of search

tasks

– „Peering over the rim of

the proverbial tea cup“

Monitoring Radar(example)

long-term

medium-termshort-term

Key competence areas

Areas of basic technologies

Areas of interdisciplinary technologies

Grinding

Precise lasermachining

Foamingof metals

Laser-welding

Thixoforming

Steel

Glueing

Forming

Welding

Timing perspective

ControlledMetal Build

up

Hydrojet-

Cutting

Aluminium-machining

Eroding

Tools

Ceramic-machining

Plasticsprocessing

long-term

medium-termshort-term

HSC-machining

Trochoidalmachining



Exercise 2


Sources of information

� Internal information network

– Colleagues, technology experts, working groups

– Internal data, protocols, earlier projects

� External sources

– Research institutes, universities

– Suppliers, cooperation partners

– Customers

– Agencies

– Patent analysis, databases, internet

� Structured investigation of technologies

– Questioning of experts

– Visit of fairs, seminats and conferences

– Analysis of competition

– Consideration of analogies

– Reference applications



Exercise 2


Determine

Information need

Gather

information

Assess

Information

Communicate

key learnings

System-based focusing

Patent analysis Workshops Expert

surveys

Portfolio Analysis Technicalevolution

Other

roadmaps

Technology

Data Sheets

Technology identification (Examples of methods)

Comments:



Exercise 2


Informationen beschaffen mittels Scanning,

Monitoring und Scouting

Monitoring

Scanning

Scouting

Task AimPerspectiveObject

Technology-relatedbusiness environment

certaintechnology areas

certaintechnology topics and knowledge carriers

Nondirectional and unfocussed

source: Ashton/Klavans 1997

Overview of global Technology trends

Directional and weaklyfocussed

Following the eventsin relevant fields oftechnology

Assigned acquisitionof detailed technologyinformation

Directional and stronglyfocussed



Exercise 2


Example consumer goods:

Analysis of potential for lightweight construction

Experts

Institutes/

Organisations

Agencies/ associations

RWTH-Network

Industrial companies/

Partner companies

Project experiences

Norms (DIN 8580)

Internet

Datbases

Fhg-Network

Examples from

different areas

Events/ fairsBrainstorming / collection of information

on lightweight construction & technology

34 approaches

20 ideas after priorization

Specification of priorized approaches and

identification of 8 additional ideas

28 Ideas

3 technologies for detailed analysis

1 technology as R&D project

Literature



Exercise 2


Technology assignment

Object of examination Analogy to

Nail production

Current production chain Alternative technology chain

Turbine production: Rivetting Turbine production: Pressure joining

Pump production: Gluing

Halogen lamp production

Pump production

Peak drawingmax 1000 pcs./min

Rotary swagingmax 80 pcs./min

Legend: b: blading d: drilling e: threading f: pressure joining h: hardeningj: alignment k: gluing l: hard soldering n: rivetting p: packetings: blanking v: copperplating

� Different concepts for

realisation of current and

future projects are

available

� Systematic forecasting

and investigation

identifies technology

alternatives

� Technologies/ technology

chains are assigned to

product concepts

��Aim: Alignment of

product specifications

and technologies!

Generation of possible technology chains

Abstract product specifications

s v p b l s b k h

d j e n f

Comments:



Exercise 2


Technology assessment: Portfolio technique

Technologieportfolio

Relative Technologieposition

Te

chn

olo

gie

attra

ktivitä

t

0,0

1,0

2,0

3,0

4,0

5,0

0,0 1,0 2,0 3,0 4,0 5,0

Konzept B

Konzept C

Konzept A

Marktportfolio

Relativer Wettbewerbsvorteil

Ma

rkta

ttra

ktivitä

t

0,0

1,0

2,0

3,0

4,0

5,0

0,0 1,0 2,0 3,0 4,0 5,0

Konzept B

Konzept C

Konzept A

Attraktivität

Ris

iko

Risikoportfolio

0,0

1,0

2,0

3,0

4,0

5,0

0,0 1,0 2,0 3,0 4,0 5,0

KonzeptC

Konzept B

KonzeptA

Ertragsportfolio

Erfolgswahrscheinlichkeit

Ert

rag

spo

ten

zia

l

0,0

1,0

2,0

3,0

4,0

5,0

0,0 1,0 2,0 3,0 4,0 5,0

KonzeptA

Konzept B

Konzept C

� Transparent and comprehensible assessment,

prioritisation and selection of technologies and projects

� Focused resource allocation

� Regarding technological and economical criteria

� Company-specific selection of assessment criteria

� Holistic, but still focused technology and project

assessment

� Use of portfolios as means of information transparency

and communication

� Constructive discourse instead of simplistic key figures

Technology portfolio

Market portfolio

Risk portfolio

Earnings portfolio

Comparative

technology position

Success probability

Technology attractiveness

Comparative competitive

advantage

Mark

et

att

ractiven

ess

Ris

k

Earn

ing

sp

ote

ntia

l

Comments:



Exercise 2


Technology assessment: Proceeding

� Benefit criteria, e.g.:

– cycle times

– max. output/time

– Quality (z.B. scrap rate)

� Effort criteria, e.g.:

– Acquisition costs

– Investment

– Consumables

� Elimination of technologies which

– do not fullfil k.o. criteria

– are significantly dominated by alternative technologies in all

criteria

– if patented, are not available for acquisition (e.g. license)

� Assessment of remaining technologies

� Summary of criteria to dimensions benefits and efforts, e.g. with

value benefit analysis

Definition of assessment

criteria

� k.o. criteria

� scalable criteria

Technology assessment

Ben

efi

t

Efforthigh

hig

h

medium

me

diu

mlo

w

low

3

14

2

67

8

9

10

1213

1415

16

1819

20

21

22

2425

26

27

17

Comments:



Exercise 2


Communicating the findings:

Idea datasheets (examples)

Pro‘s and con‘s

Short description

Available technology experts

Related parts

Aluminum foams

ALuminum-Magnesium coatings

Short description



Exercise 2


Realisation planning: Example: Technology calendar fuel cell

Proceeding

� Deduction of technology acquisition demand

� Identification of technology sources:– in-house development

– Mergers & acquisitions

– Joint Ventures

– Development cooperations

– External development

– Technology licensing

� Determination of timing, milestones and fall-back

solutions

Results

� Deducted development projects

� Technology acquisition activities

� Timing alignment between product and technology

portfolio

Comments:



Exercise 2


Structure

Introduction of the technology calendar1

Case study: A380 engine components2



Exercise 2


Case study: Airbus A380 Technology calendar for engine components

GP7000 (General Electric)Airbus A380

Source: General Electric

Source: Rolls-Royce

Trent 900 (Rolls-Royce)

� Both competitors equally share the market

� Airlines decide which engines they want to use

� Success factors:

– Specific Fuel Consumption (SFC)

– Overall weight

– „Cost per flight hour“

– Noise

Source: EADS

Comments:



Exercise 2


Principle of function: Turbofan engine

� Main use: Civil aviation

� High bypass air flow

� Process comparable to 4-cycle

engine, but all processes

happen in parallel:

– Compress (1)

– Combust (2)

– Expand (3)

– Eject (4)

� Compressor consists of up to 9

stages

� Turbine consists of up to

7 stages

� each stage

= Disc + blades, or

= Blisk (Integrally bladed disc) 1

Compress

2

Combust

3

Expand

4

Eject

Bypass air flow

Comments:



Exercise 2


Blade-disc-systems vs. blisk (blade integrated disk)

Blade on disc withfoot profile

Blisk (welded blades)

� Blade foot profile is pressed into disc profile,

then form-locked against axial movement

� No alternative to blade-disc-system for hollow

blades with cooling holes

� Welded blades or alternatively milling from solid

(very expensive, esp. used for highly stressed

parts (e.g. monocrystalline materials))

� In the case study, stage 2 of the compressor is

going to be a blisk from September 2008 and

will fully substitute the old technology 9 months

later

Source: Blacks Equipment Ltd & MTU

Comments:



Exercise 2


Conventional technology: Blade-disc-systems

Source: Rolls Royce

� One compressor blade of 10 cm length delivers as much

power as a Formula 1 racing car

� Gas temperatures in turbine partially exceed melting

temperature of blade alloys

�Cooling holes and blade coatings lower surface

temperature

� Cooling holes are manufactured by Electrical Discharge

Machining (EDM) or laser drilling

� Use of blisks only feasible for uncooled blades!

Comments:



Exercise 2


High importance of after-sales for engine manufacturers

� Lifecycle of aircrafts: approx. 20 years

� High attrition of engine components

� Engines to be maintained yearly, first review of engineblades 6 months after start of operation

� After-sales business amounts to more than 60% of engine manufacturers‘ turnover

� Blisk reparation process:

� Large defects: Milling of weared-out blades and weldingof new blades

and/ or:

� Smaller defects: Deposit welding at attrition spots and regrinding

Quelle: Rolls-Royce

Engine manufacturers often provide engines for free to the aircraft manufacturers, so thatthe turnover only comes from the after-sales business!

Comments:



Exercise 2


Structure of the technology calendar (template)

2009 2012 t

Pro

ducts

Technolo

gie

s

2010 2011

Rep

air

New

part

s

� Date of planning:

November 2009

Comments:



Exercise 2


Technology identification for blisk production:Definition of search areas

� Minimal hardness and microstructure within component

(component is safety-critical!)

� high accuracy regarding rotational movement

� Joining technologies

� Stripping (starting from solid)

� Joining and stripping technologies in fields of

– Automotive (turbocharger, cycle engines etc.)

– Pump systems (rotors)

– Tool & Die Making

– Process engineering applications

(pressure tanks)

Definition of requirements

Technical alternatives

Deducted search areas

Comments:



Exercise 2


Technology identification for blisk production:Results of technology investigation

Joining technologies

� Linear friction welding

� Stir friction welding

� Laser-assisted stir friction welding

� Laser welding

� High frequency press welding

� Inductive welding

� Hard soldering

� Laser soldering

� Laser powder build up welding

Stripping technologies

� (Conventional) Grinding

� (Conventional) Milling

� Trochoid Milling

� High Speed Cutting (HSC)

� Eletrical Discharge Machining (EDM)

� Electro-Chemical Machining (ECM)

Comments:



Exercise 2


Technology assignment

2009 2012 t

Pro

ducts

Technolo

gie

s

Blade Stage 2

Disc Stage 2Compressor blisk 2

2010 2011

Rep

air

New

part

s

� Adequate technologies for

new part manufacturing:

– Electro-Chemical Machining

(ECM)

– Linear friction welding

� Adequate technologies for

blisk reparation:

– (Conventional) milling

– Linear friction welding

– Laser build-up welding

– (Conventional) grinding

production at max. level:

6/2011

planned start of production: 9/2010

first parts in reparation: 3/2011

Comments:



Exercise 2


Technology assessment: Blisk manufacturing

� Redox reaction of blisk (anode) and tool (cathode) in electrolyte (NaCl)

� Expensive (high power demand), suitable only for smallproduction volumes

� metalhydroxid slurry is harmful for the environment

� R&D time schedule till series use: 6 months

� Blisk joining from disc with foot sockets and blades

� Linear frictive movement causes heat and melting of material at contact area

� Suitable for high and low volumes

� Also suitable for repair of blisks (Exchange of blades)

� R&D time schedule till series use : 12 months

Linear friction welding

Electro-Chemical

Machining (ECM)

Comments:



Exercise 2


Technology assessment: Blisk reparation

� see: blisk manufacturing

� Repair technology for blisks to compensate lost material (e.g. edge breakouts, edge wear)

� Following grinding creates final shape

� Technology is patented by an external company and isdistributed via licensing

� Process integration of technology into existing processchain necessary

� Time for process integration: 2 months

� established technologies

� R&D unnecessary


Laser build-up welding

Grinding & Milling

Comments:



Exercise 2


Realisation planning: technology calendar

2006

Pro

ducts

Technolo

gie

s

2007

Deduction of activities in

the technology calendar

�Adding relevant

Product informationen

(Start of production etc.)

�Definition of necessary

time for R&D and

integration projects

Rep

air

New

part

s

Laser build-up welding



ECM

Grinding & Milling

t

Blade Stage 2

Disc Stage 2Compressor blisk 2

production at max. level:

6/2011

planned start of production: 9/2010

first parts in reparation: 3/2011

2009 20122010 2011

Comments:



Exercise 2


Conclusion: Use of methods in technology management…

� creates transparency for management

� helps to trace back decisions

� supports to cope with complexity

� optimises the coordination of diversified activities

� encourages communication within company and supply

chain

� supports operationalisation of strategic objectives

� systemises the creation and protection of technology-

based competitive advantages

Comments:

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