Design Engineering (cont.)

1. #1 ( The “problem”) is usually handed to the designer, especially in the academic setting (engineering curriculum) #2 - #4 (Applying the laws of physics, solving equations, creating the best design solution) are what engineers learn to do! The Essence of Design Engineering Define the problem Understand the relevant laws of physics (equations) Learn/develop methods for solving the equations Creatively apply the laws of physics to obtain the best design solution for the problem Design Engineering (cont.)

2. The Essence of Design Engineering Define the problem Understand the relevant laws of physics (equations) Learn/develop methods for solving the equations Creatively apply the laws of physics to obtain the best design solution for the problem How is Lean Engineering Different? Lean principles can provide a broader, more efficient way of defining the problem Skills in handling #2-#4 remain the majority of the designer’s effort The end product is more efficient, therefore more competitive!! Lean Engineering Provides A Better Perspective!

3. Lean Enterprise Lean Suppliers Lean Engineering Lean Manufacturing

4. Cost-Price Relationship The fundamental cost –price relationship has changed in the defense industry in the last 15 years ! price profit 15% cost price customer is willing to pay profit cost customer-determined price(industry must lower costs to achieve profit!) “cost plus” profitequals price

5. Systems Engineering Using systems engineering, engineers must “translate” customer’s requirements into an architecture and set of technical specifications that allow us todesign for the product performance, reliability,maintainability, unit cost, growth/scalability, lifecycle cost and supportabilitythat thecustomer specified in their concept of“value”. “Design for X”

6. Lean Engineering • 80% of a product’s cost is determined by the engineering design: • Number of parts • Assembly technique (fasteners, EB welding, co-cure, etc.) • Processes (heat treat, shot peen, CAD plate, etc.) • Tooling approach (matched metal dies, injection molding, etc.) • Materials (titanium, aluminum, composites, etc.) • Tolerances Engineers must design for manufacture/assembly !

7. Lean Engineering • Design for manufacture and assembly (DFMA) • Parts reduction • Get rid of threaded fasteners • Standard parts and specifications • Economical procurement • Reduced inventory • Reduced production control • Design re-use: Save NC programming, tooling and improve reliability

8. Lean Engineering • Give manufacturing and supplier management: • Fewer parts • Designed with high quality (that fit the first time!) • Robust fabrication/assembly processes

9. F/A-18E/F Super Hornet

10. Design for ManufacturingHas Reduced F/A-18E/F Parts Count Forward Fuselage and Equipment Wings and Horizontal Tails C/D Parts 5,907 E/F Parts 4,046 C/D Parts 1,774 E/F Parts 1,268 Center/Aft Fuselage, Vertical Tails and Systems C/D Parts 5,500 E/F Parts 3,494 Total C/D Parts E/F Parts 14,104 8,099 E/F 25% larger and 42% fewer parts than C/D!

11. USAF C-17

12. C-17 MLG Pod Redesign • Approach • Minimize fuselage attach points • Combine 3-piece pod into one • One-piece machinings vs.sheet metal buildup • Multi-disciplined DFMAstudy team • Results • Pod installation • Parts reduced by 48% • Fasteners reduced by 76% • Pod assembly • Parts reduced by 41% • Fasteners reduced by 17% • 17/20 PTOs used as production parts • Installation results • 80% reduction in hours • 90% reduction in defects

13. Traditional hollow core, air cooled gas turbine blades were: Designed using rough castings, infiltrated with metal matrix to withstand coarse machining loads Rough machined Fine machined Metal matrix removed Finish ground Lean design utilizes near net shape castings Turbine Blade Design Value added times are reduced to 10 minutes per blade and yields exceed 90%. Typical value added times were 2 hours and first pass yields as low as 50%.

14. Traditional designs Separate front and back plates and numerous airfoil-shaped vanes Require precise tooling for accurate positioning during the brazing assembly process Lean design Numerical controlled machining of the vanes and one endplate out of a solid metal blank Other endplate is simply brazed to the vane structure Only two parts are required and fixturing is minimized Centrifugal Impeller Design Typical value added times of 4 hours and first pass yields as low as 10% result. One hour of value added time and yields approaching 100% result.

15. Aircraft electrical power is generally provided by alternators mounted to engine accessory gearboxes and using a number of threaded studs and lock nuts Typically this involves multiple parts and assembly times on the order of 2 minutes per fastener Lean design utilizes a single barrel clamp and fastener Eliminates up to 90% of the parts and assembly time It also provides benefits during maintenance Engine Alternator Assembly

16. Lean Engineering • An integrated multi-discipline team approach • Responsibility, accountability, and authority for: • product performance • cost • schedule • Passion for affordability! The role of integrated product development in achieving affordable results!

17. Layout PACKS Part Surfacer Parametric Solid Models BTP Release Assembly Models Smart Fastener Assy/Manf Simulation Virtual Reality Reviews Hardware Integrated Solids-Based Design, Validation, and Build • IPT Team : • Design • Strength • Sub-Systems • Fab & Assy • Suppliers • M&P • Mass Properties • SM&P Suppliers are key to solids-based define and build approach

18. Design Data File (DDF) FeatureFreeze Optimization Final Geometry On-Dock Moving At The Speed Of Parametrics 2 to 10 M-Days 5 to 20 M-Days 0.1 to 3 M-Days Under Contract Out for Bids 16 Week Average (BTP to On-Dock) On-Dock in Half the Time