This paper deals with factory and process simulation at an early stage of product introduction. During this stage basic considerations about producibility and impact on factory and supply chain logistics are of utter importance. Steps required to develop a realistic imitation of an (in this case) engine manufacturer plant are discussed. It is laid out how time variances, machine breakdowns as well as historic process capability and quality data can be included to create a model, which is able to realistically predict the impact of the introduction of new products. A feature-based approach to evaluate process capability for new products which have to be introduced is described. An example is given by the application of this approach to a modern engine high pressure compressor drum. A factory simulation in aero-engine component manufacturing needs to take into account the peculiarities of this industry: High amount of rework. Highly skilled but specialized workforce. Complex products and processes. If these factors are not included in a factory model, it will give a false impression of the possible performance of a plant. Based on the implementation of process capability, manufacturing methods and design options can be effectively evaluated with regards to their impact on manufacturing performance. For the future, it would be worthwhile to build up a process capability database. This would make it easier to analyze and model process capability for similar features. Also, the use of process capability indices in a low-volume environment needs further investigation.
Factory and process simulation in aero-engine component manufacturing
Fabrik- und Prozesssimulation in der Fertigung von Flugtriebwerkskomponenten
ASME Turbo Expo, 2005 ; 77-84
2005
8 Seiten, 10 Bilder, 15 Quellen
Conference paper
English
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