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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
HELICOPTER
PRE-DESIGN PROCESS
IMPROVEMENT
M. GREILLER (Eurocopter)
VI VACE For um 1, War w i c k UK, 20-21 Sept ember 2005
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Table of contents
HELICOPTER INDUSTRY PARTICULARITIES
Multiple customers and missions
Market characteristics
Heavy development
DEVELOPMENT PROCESS DESCRIPTION
General development process
Pre-Design process
USE CASE DESCRIPTION
AS-IS pre-design process
TO-BE pre-design process
Benefits
SCENARIOS
Mastering uncertainty
General architecture
Life Cycle Cost
Visualisation & selection
ROADMAP
W
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Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
HELICOPTER INDUSTRY PARTICULARITIES
Commercial companies offering regular
flights (Off-shore, commuters)
Customers :
Charter or private owners
Military or public customers
Multiple customers and missions
Search and Rescue
Missions :
Off-shore or commuter
Military missions
Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Very small series
Many versions for the same type of helicopter
Low self financing capacity
Due to the small series, the recurrent costs and the sale prices cant be
reduced.
Fewer major national programs
Decrease of great National contracts
(usually military ones)
Market characteristics
HELICOPTER INDUSTRY PARTICULARITIES
Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Complex air wake generated by the
main rotor
Behavior simulation difficulties
Numerous modifications during the
development phase due to:
- Vibrations
- Flight qualities
- Icing
- Wake interactions
Parts generally reworked :
- Position of the horizontal stabiliser
- Anti-vibration devices
- Air intakes
- Upper cowlings
Heavy development
HELICOPTER INDUSTRY PARTICULARITIES
Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
DEVELOPMENT PROCESS
General development process
Feasibility
Pre-Development
Development
Industrialisation
Service life support
Pre-Design process
Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Feasibility (Managed by Pre-project team)
Actors:
- Pre-project team,
- Strategy,
- Marketing and sales,
- Finance.
Results:
- Top level requirements,
- Technical feasibility document,
- Business case.
PRE-DESIGN PROCESS
Pre-Development (Managed by Program team)
Actors (those above and):
-Project management
-Technical specialists
-Purchasers
-Production
Results:
-Global aircraft and major sub-
systems specification frozen.
-Major interfaces frozen,
-Major subcontractors chosen,
-Risk management Plan,
-Business case (complete)
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
AS-IS Pre-design process
USE CASE DESCRIPTION
TO-BE Pre-design process
Main risks and
opportunities:
Identification
and assessment
with a new
process
General architecture definition:
- Customers requirements fulfillment
- Simplification of the helicopter
integration
Costs evaluation :
Assessment and
optimization for a
large panel of
customers and/or
mission
Main risks and
opportunities:
Coming from
experience of some
specialists
Costs evaluation :
For each
customer and/or
mission
General architecture definition:
- New products derived from existing
products.
- Not complete pre-design phase, with
high level of risks.
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
USE CASE DESCRIPTION
BENEFIT
Spend more time and money during this first phase, in order to avoid a re-
design later.
HOW
By using the 4 following scenarios
1. Mastering the uncertainty
2. General architecture
3. Life Cycle Cost
4. Visualisation and selection
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
SCENARIO 1. Mastering uncertainty
Scope :
AS-IS Process
TO-BE Process
Data provided without assessment of their uncertainty.
All values could be very lower or higher than the good data.
Its mandatory to identify, categorise and quantify the
main risks or opportunities before sending data
Provide common methodology to express and
assess the uncertainty of numerical data.
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
- 1 - Identify
and categorise
all the types of
risks
- 2 - Map those
Risks and trace their
interdependencies.
- 3 - Evaluate the
existing probabilistic
tool and make a
selection.
- 4 - Build
a technical
example
- 5 - Perform
sensitivity analysis
of the example
- 6 - Conclude with
the benefit and the
limits of themethod
Scenario description :
SCENARIO 1. Mastering uncertainty
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Today reference
Arithmetical sumof the elementary margins to
ensure usual level of confidence for sub-parts
Objective
Save 20-30%of the standard margins
Criteria - Metrics
Identify and quantify
R-O*
Categorise R-O* and trace
their interdependencies
Aggregate elementary
R-O*
Service functions
Criteria
Margin to ensure usual level of confidence
(90%)
Perform sensitivity
analysis
Link back-up solutions
* R-O = Risks or
Opportunities
SCENARIO 1. Mastering uncertainty
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
This scenario is linked with WP3.3 through the
following activities
(Design to Decision Objectives)
Analyse the state
of art and propose
adapted solutions
Help to identify,
categorise and map the
generic risks and
opportunities
Evaluate the existing
probabilistic tool and
propose a selection
Contributions
Help for sensitivity
analysis
SCENARIO 1. Mastering uncertainty
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Scope
To
formalise
To
make
explicit
The purpose
of this
scenario is
The steps of the elaboration process for
a global aircraft architecture
and
SCENARIO 2. General Architecture
Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
TO-BE process :
Pre-Project
team
Experience
feed-back
data base
and tools
Elaboration of balanced architectures for new helicopters
40%
60%
Experience
of involved
people
The definition
Result of pre-project phase
The technical
specifications
Context Hypothesis Choices
Forgotten parameters
AS-IS process
SCENARIO 2. General Architecture
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
- 1 -Collecting
the Know-How
of specialists
- 2 - Collecting
main justifications of
general architecture
- 3 - Formalising
these informations
for a further re-use
- 4 -Developing of
a tool to link the
inter-connected
subjects
- 6 - Defining and
formalising the
criteria to assess an
architecture.
- 5 - Identifying the
major topics or
problematics,
addressed by the
general architecture
process
Scenario description
SCENARIO 2. General Architecture
Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Criteria
Time to elaborate a new architecture
Today reference
About 1 year for experienced people
Objective
About 9 months
Criteria - Metrics
Service functions of the developed tool
Identify and capitalise
the Know-How of
experienced people
Make this Know-How
usable for non-specialists
Propose a formal model
to elaborate an
architecture
Service functions
SCENARIO 2. General Architecture
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
This scenario is linked with WP3.3 through the
following activities
(Design to Decision Objectives)
Define an adequate
structure for the
Know-How data-base
Define the tools to
link the inter-
connected subjects
Formalise the
general architecture
process
Contributions
SCENARIO 2. General Architecture
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Scope
Optimising the technical definition of a helicopter for :
- Different customers -
- Different requirements -
- Opposite profiles -
AS-IS &TO BE processes
Market analysis for many
customers, for only one definition
Cost estimation based on the
most critical mission
Economical impact estimation for
all the categories of customers
Market analysis for all
customers and all missions
AS-IS TO-BE
Technical choices
(which involve a cost aspect)
SCENARIO 3. Life Cycle Cost
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
- 1 - Define
the categories
of customer
- 2 - Adapt the sizing
models of NLR and EC:
find a common list of
technical parameters
- 3 - Develop
the cost model
- 4 - Perform sensitivity
analysis on a limited
number of parameters
- 5 - Optimise helicopter
definition for LCC of 1
customer first.
- 6 - Define a criteria
to combine LCC of
multiple customers &
missions
- 7 - Optimise
helicopter definition
for this composite
criteria
Scenario description
SCENARIO 3. Life Cycle Cost
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Criteria
Time to perform combined technical & market analysis
Today reference
1 2 weeks
(Models not complete or not connected)
Objective
1 Day
Criteria - Metrics
Service functions of the developed tool
Estimate the LCC of any
technical definition for
any customers profile
Perform sensitivity
analysis
Optimise helicopter
definition for LCC of 1 or
multiple customers &
missions
Service functions
SCENARIO 3. Life Cycle Cost
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Adapt the sizing
tool for cost
calculations
Connect the
sizing tool with
the cost model
Define the multi-
criteria optimisation
method
Contributions
This scenario is linked with WP3.2 through the
following activities
(Multidisciplinary Design & Optimisation)
Perform the
sensitivity
analysis
SCENARIO 3. Life Cycle Cost
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Scope :
Visualisation of complete helicopter geometric models with:
- Short access time -
- Focusing only on interesting areas -
- High precision -
AS-IS &TO BE processes :
The size of the models are too much
important for a complete helicopter
Models are too long to be visualised
with usual CAD tools
Capability to visualise any part of
an helicopter in its context.
Perform general architecture studies
AS-IS TO-BE
Only used for details studies, or with
rough models for complete helicopters
Visualisation of an entire digital
mock-up
SCENARIO 4. Visualisation and selection
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Scenario description:
- 1 - Evaluate
existing
visualisation
tools
- 2 - Define
methodology to use
those models
- 3 - Select an existing
tool or write an user
specification for
further tools.
SCENARIO 4. Visualisation and selection
Photos EUROCOPTER
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
Criteria
Time to visualise typical complete helicopter model
Today reference
About 1 hour
Objective
Few seconds
Criteria - Metrics
Service functions of the developed tool
Visualise and animate
models of complete
helicopters,
Refine selected
areas up to
elementary items
Service functions
Automatically
simplify native
models
SCENARIO 4. Visualisation and selection
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HELICOPTER
PRE-DESIGN PROCESS IMPROVEMENT
Warwick UK, 20 &21 September 2005
VIVACE Forum-1
ROADMAP
First
prototype
release
Solutions
assessment &
selection
SEEMAGE software evaluation in
progress.
Requirements
and
specifications
report
DONE
4. Visualisation and selection
First
prototype
release
Solutions
assessment &
selection
A helicopter Life Cycle Cost model
was sent to NLR in order to integrate
it into the NLR sizing tool SPEAR
tool.
Requirements
and
specifications
report
DONE
3. Life Cycle Cost
First
prototype
release
Solutions
assessment &
selection
Assessment of a forecasted solution
using INGENIUM software, in
progress
Requirements
and
specifications
report
DONE
2. General architecture
First
prototype
release
Solutions
assessment &
selection
WP3.3 solutions assessment in
progress.
Requirements
and
specifications
report
DONE
1. Mastering the uncertainty
M30
(Deliverable)
M24
(Deliverable)
M21
M12
(Deliverable)
SCENARIO