Implementing a Design to Cost Strategy in a Complex Aerospace Design Project Aerospace ...

102 Pages·2015·33.75 MB·English

by  Andre C. Marta

Implementing a Design to Cost Strategy in a Complex
Aerospace Design Project
Sebastião Pedro Arrais Ivens Collares Pereira
Thesis to obtain the Master of Science Degree in
Aerospace Engineering
Supervisor: Prof. Fernando José Parracho Lau
Examination Committee
Chairperson: Prof. Filipe Szolnoky Ramos Pinto Cunha
Supervisor: Prof. Fernando José Parracho Lau
Member of the Committee: Prof. Paulo Miguel Nogueira Peças
March 2015
ii
Dedicatedtothe”A320/A330PAXO2Containers”Team
iii
iv
Acknowledgments
For this dissertation and during the course of a 6-month final studies’ internship at Zodiac Oxygen
Systems(ZOS)Iwouldliketomakethefollowingacknowledgements:
I would like to thank all the ZOS team that welcomed me in an impeccable way. I got the chance
to understand, in first hand, why Zodiac Aerospace is one of the most important companies in the
Aeronautical sector: It is a company of inspiring people with a passion for Aeronautics, fully dedicated
todevelopthebestproductsinthesector.
Inparticular,IwouldliketothanktoAndreasJauslin,mysupervisorandmentorduringmyinternship
atZodiacOxygenSystems. Icouldn’thaveaskedforabettersupervisor! Youarebrilliantineverything
youdoanditwasapleasuretoworkwithyou. Youmademefeelwelcomefromtheveryfirstday. Thank
youforyourpatienceandthankyouforsharingwithmeyourpassionandknowledgeintheartofproject
management.
I also would like to thank to Professor Philippe Girard (ISAE - SUPAERO) for the guiding, compre-
hensionandadviceontheinternship.
ToProfessorFernandoLau(IST)forallthehelpandadviceincompilingandrevisingthiswork.
To all the members of the ”A320/A330 PAX O2 Containers” project team without whom this work
wouldn’t be possible. Notably I would like to thank to: Pierre-Antoine Muller, Antoine Lehoux, Jeroen
VanSchaik, Benoit Le-Lie`vre, Susann von Wolffersdorff, Frederic Raoul, Baptiste Jarrassier, Sylvain
Marmoiton,EtienneMorvanandChristopheDolle.
Finally,Iwouldliketothanktomyfamilyforthecontinuoussupportandaffection,alwaysmotivating
meinthepursuitofmydreams.
v
vi
Resumo
O aumento da competitividade no mercado da aviac¸a˜o comercial, juntamente com a necessidade do
cliente (companhias ae´reas) em reduzir custos operacionais, levaram a uma mudanc¸a na forma como
osprodutossa˜odesenlvolvidosnaindu´striaaeroespacial. Osectoraerospacialtemprocuradoadoptar
novas estrate´gias de desenvolvimento de produtos de forma a alcanc¸ar designs de qualidade a custo
reduzido. Uma destas estrate´gias e´ a a estrate´gia “Design to Cost” (DTC) que tem por objectivo o
desenvolvimento de um produto segundo um conjunto de requisitos, sem ultrapassar um determinado
custoobjetivo.
Este trabalho abordara´ o processo de implementc¸a˜o de uma estrate´gia DTC no contexto de um
projeto aeroespacial complexo – o novo sistema de oxige´nio de emergeˆncia para os passageiros de-
senvolvidopelaZodiacOxygenSystems(filialdogrupoZodiacAerospace).
A implementac¸a˜o da estrate´gia DTC foi ajustada a`s necessidades do projeto e foi resultado da
adaptac¸a˜o de um me´todo cla´ssico de ”Design for Manufacture” (DFM). Um conjunto de ferramentas
bemcomoumme´todopra´ticoforamdesenvolvidosparagarantirosucessonaexecuc¸a˜odaestrate´gia
implementada.
Finalmente, demonstrar-se-a` que o me´todo DTC implementado resulta numa reduc¸a˜o de custos
substancial para a empresa e, que pode ser facilmente adaptado para o controlo de outras varia´veis
de importaˆncia no sector aerospacial como a massa, despesas de capital e o tempo de montagem do
produto.
Palavras-chave:
Design to Cost, Projeto Aeroespacial Complexo, Custo Objetivo, Zodiac
OxygenSystems
vii
viii
Abstract
Theincreasingcompetitivenessinthecommercialaircraftmarket,alongwithanexplicitneedofthecus-
tomer(theairlines)forreducedoperatingcostsandlead-time,makeforashiftonthewayproductsare
developed and designed by aerospace Original Equipment Manufacturers (OEM). In order to achieve
cheaper and more affordable designs that don’t compromise reliability and quality, the aerospace in-
dustryhasadaptedcoststrategieslongusedinothersectors/industries. Oneofthesestrategiesisthe
DesigntoCost(DTC)approachthataimstoprovideadesignthatsatisfiestherequirementsforagiven
costtarget.
ThisworkwilladdresstheprocessofimplementationofasuccessfulDTCstrategyinthecontextof
acomplexaerospaceproject–thenew60-minoxygensupplyunitsbeingdevelopedbyZodiacOxygen
Systems–abusinessunitoftheZodiacAerospacegroup.
The implemented DTC strategy was adjusted to the needs of the project with the adaptation of a
classicalDesignforManufacturemethod(DFM).Apracticalmethodforimplementationoftheapproach
wascreatedaswellasasetofprojectmanagementtoolstogovernthestrategy.
Finally, it will be shown that the implemented DTC method can result in significant cost gains for
the company as well as be easily adapted to control and provide gains on other important aerospace
variablessuchasmass,CapitalExpenditure(CAPEX)andassemblytime.
Keywords:
DesigntoCost,ComplexAerospaceProject,Costtarget,ZodiacOxygenSystems
ix
x