Innovation and Training at Aerosud by Dr K Van Rijswijk

Enhancing people, improving technologyEnhancing people, improving technology

Innovation and Training at Innovation and Training at AerosudAerosud

Dr. K. van RijswijkDr. K. van Rijswijk

Monday, April 10, 2023

Materials Processes

Design

SATN Annual Conference 2009SATN Annual Conference 200916-17 July16-17 JulyCape Peninsula University of TechnologyCape Peninsula University of TechnologyBellville CampusBellville Campus

Monday, April 10, 2023Monday, April 10, 2023 22/33/33


OutlineOutline

• Introduction AerosudIntroduction Aerosud• Stability vs. ChangeStability vs. Change• Aerosud Innovation & Training CentreAerosud Innovation & Training Centre• Example of InnovationExample of Innovation• UoT student characterizationUoT student characterization• ConclusionsConclusions• Questions / discussionQuestions / discussion



Introduction AerosudIntroduction Aerosud• Formed in 1990Formed in 1990• Strong Engineering Design Capability Strong Engineering Design Capability • Production => 750,000 Details/Assy’s per yearProduction => 750,000 Details/Assy’s per year• 600 Staff 600 Staff • 95% Export95% Export



Introduction AerosudIntroduction Aerosud

• Aerosud Holdings:Aerosud Holdings:– Aerosud Aerospace Systems: Aerosud Aerospace Systems:

• Military UpgradesMilitary Upgrades

– Aerosud Aviation:Aerosud Aviation:• Design and Manufacture of Aircraft structures and interiorsDesign and Manufacture of Aircraft structures and interiors

– Aerosud Innovation and Training Centre:Aerosud Innovation and Training Centre:• R&D, HCDR&D, HCD



Introduction AerosudIntroduction Aerosud

Build-to-Print

Subcontract Design &

Manufacture

Risk-sharing Partnership

Product Ownership

Product Ownership

??

Galleys

Mil. Upgrades

A400M

A350

787

Boeing

BAE Systems

Boeing

Airbus

Etc etc

“Innovate to prevent that contract is moved to a lower wage country”

“Innovate to maintain or increase market share”

“Innovate to become a more attractive partner in

challenging projects”



Stability vs. ChangeStability vs. Change

Continuous quality is one of the most important aspects Continuous quality is one of the most important aspects of aeronautical engineering:of aeronautical engineering:– Rules and regulationsRules and regulations– Certified processes, materials and personnelCertified processes, materials and personnel– Records, paperwork and traceabilityRecords, paperwork and traceability– Testing and proof of complianceTesting and proof of compliance

EASA Part 21 POAAS/EN9100

Production requires a stable environment:

“Always the same”

Production requires a stable environment:

“Always the same”




Innovation is an equally important aspect:Innovation is an equally important aspect:– New materialsNew materials– New manufacturing processesNew manufacturing processes– New designs and applicationNew designs and application– New management systemsNew management systems– New marketing methodsNew marketing methods– Knowing what the customer is going to want (trends) before he Knowing what the customer is going to want (trends) before he

places an order: Can you guys make…Yes we can!places an order: Can you guys make…Yes we can!– ……

Innovation requires a dynamic environment:

“Continuous change”

Innovation requires a dynamic environment:

“Continuous change”




Production (Always the same) and Innovation Production (Always the same) and Innovation (Continuous change) must not contaminate each (Continuous change) must not contaminate each other:other:– Spontaneous innovation might threaten stable Spontaneous innovation might threaten stable

productionproduction– Focusing on stable production might push innovation Focusing on stable production might push innovation

asideaside

Specialization!... Specialization!... With communication and an overlapWith communication and an overlap




Stability Change

Production Innovation

Proven technology New technology

Repeatability Feasibility

Communication



Aerosud ITCAerosud ITC

Aerosud Innovation & Training Centre:Aerosud Innovation & Training Centre:Process DevelopmentProcess Development

– Advanced Composite TechnologyAdvanced Composite Technology– High-Speed MachiningHigh-Speed Machining



Aerosud ITCAerosud ITC

Development of new material applications and Development of new material applications and manufacturing technologies:manufacturing technologies:

““Saving time, costs and weight.”Saving time, costs and weight.”

Developing applications to maximize the benefit of Developing applications to maximize the benefit of the above mentioned technologies.the above mentioned technologies.

Training people at the same time to implement Training people at the same time to implement new technologies in the workshops.new technologies in the workshops.



Ingredients for InnovationIngredients for Innovation

• Broad knowledge baseBroad knowledge base

• Customers (for who…?)Customers (for who…?)

• A network of experts (co-operation)A network of experts (co-operation)

• FundingFunding

• InfrastructureInfrastructure

• Implementation strategyImplementation strategy

• Adventurous mind-setAdventurous mind-set



Aerosud ITCAerosud ITCBroad knowledge baseBroad knowledge base

Materials Processes

Design



Aerosud ITCAerosud ITCBroad knowledge baseBroad knowledge base

Materials Processes

Design

Testing

Supplier relation

Manufacturing equipment

Tool design

Assembly

Finishes

Design values

Comparative studies

Qualification

Customer relation

Design rules

Processing envelope

Parameters and variables

Transport and Storage

Legislation

IP

Costs



Aerosud ITC Co-operationAerosud ITC Co-operation

US:

• Thermoplastic Composites

• Titanium Machining

CUT:

• Direct manufacture

TUT:

• Composites

• High-speed machining

CSIR:

• Composites

• High-speed machining

• Direct Manufacture

UJ:

• Composites

AMT Composites

• Material supplier

Epsilon engineering:

• Tooling manufacturer

LST:

• Composite manufacturer

ANDTc:

• NDT



FundingFunding

• Direct funding from customerDirect funding from customer• Own investmentOwn investment• Government funding:Government funding:

– AMTSAMTS– Innovation FundInnovation Fund– Teta Training grantsTeta Training grants– EU fundingEU funding– TIATIA– ……



Implementation StrategyImplementation Strategy

• Active marketing of companies to obtain Active marketing of companies to obtain contracts that involve the newly developed contracts that involve the newly developed technologiestechnologies

• Training facilitiesTraining facilities

• FundingFunding



Example of InnovationExample of Innovation

Development of a composite sliding door for Development of a composite sliding door for aircraft interiors:aircraft interiors:

• Lightweight type of garage door (no Aluminium)Lightweight type of garage door (no Aluminium)• Fully flat/smooth surface when closedFully flat/smooth surface when closed• FSTH compatibleFSTH compatible• Able to withstand a 90-kg abuse load without popping Able to withstand a 90-kg abuse load without popping

out of the railsout of the rails• 280.000 cycles (open-close)280.000 cycles (open-close)



Composite Sliding DoorComposite Sliding Door

Innovation does not have

to be “difficult”




Material Selection:Material Selection:• Bending stiffness: Composite Sandwich panelBending stiffness: Composite Sandwich panel

• Fatigue resistance: Thermoplastic composite skinFatigue resistance: Thermoplastic composite skin

• Assembly: Bonding with epoxy adhesiveAssembly: Bonding with epoxy adhesive

• Front finish: Decorative laminateFront finish: Decorative laminate

• Back finish: Flexible clothBack finish: Flexible cloth

• Side finish: Plastic cappingSide finish: Plastic capping




Mechanical testing:Mechanical testing:

““confidence tests”confidence tests”

75kg75kg75kg75kg

185kg!185kg!stiff

flexible

280.000 cycles

Cyclic testing at UoT

Static testing at ITC




Three routing concepts:Three routing concepts:

1

2

3

Routing Routing composite composite panel up to panel up to

the skinthe skin

Multi-step routingMulti-step routingBonding Bonding individual individual slats onto slats onto

flexible skinflexible skin

1 - Time-consuming1 - Time-consuming

2 - Allignment 2 - Allignment difficult to obtaindifficult to obtain Selected method




• Full scale cyclic testing at SABSFull scale cyclic testing at SABS““certification tests”certification tests”




INNOVATION?INNOVATION?



UoT Student report:UoT Student report:

• Execution of work: Execution of work: 80%80%

• Participation in innovation: Participation in innovation: 25%25%– No ideas, suggestion, thoughts, opinionsNo ideas, suggestion, thoughts, opinions– Not the proper communication skills to solve Not the proper communication skills to solve

multi-disciplinary problems:multi-disciplinary problems:• How to express yourself in a discussion?How to express yourself in a discussion?• English (grammar, terminology, formulation)English (grammar, terminology, formulation)• Report writing, summarizing, presentations Report writing, summarizing, presentations




Communication !!!!!!!!Communication !!!!!!!!

Stability Change

Production Innovation

Proven technology New technology

Repeatability Feasibility

CommunicationCommunication

Materials Processes

Design

Testing

Supplier relation

Manufacturing equipment

Tool design

Assembly

Finishes

Design values

Comparative studies

Qualification

Customer relation

Design rules

Processing envelope

Parameters and variables

Transport and Storage

Legislation

IP



Present:Present:

UoT students excel at UoT students excel at implementing implementing solutionssolutions,…but are not ,…but are not problem solversproblem solvers. .

……This does not mean that UoTs are not This does not mean that UoTs are not innovation centres, I think you are doing a innovation centres, I think you are doing a brilliant job!brilliant job!

University of Technology StudentsUniversity of Technology StudentsTechnician

level

Engineering level



Future ambition:Future ambition:• In order to move up to the engineering level:In order to move up to the engineering level:

– Actively embed “problem solving” and “innovation” in Actively embed “problem solving” and “innovation” in the curriculumthe curriculum(knowing what football is does not make you (knowing what football is does not make you automatically a football player)automatically a football player)

– Improve communication skills Improve communication skills

Trap:Trap:• If UoT students move up to the engineering If UoT students move up to the engineering

level, who will become our technicians?level, who will become our technicians?

University of Technology StudentsUniversity of Technology Students



ConclusionConclusion

Innovation:Innovation:• Is a skillIs a skill• Right guy in charge, not necessarily an expertRight guy in charge, not necessarily an expert• Essential for the survival of an industryEssential for the survival of an industry• Innovation and steady production must not contaminate Innovation and steady production must not contaminate

each other, each other, communicationcommunication is essential is essential• Network of experts is required, Network of experts is required, co-operationco-operation• UoT students can already successfully participate in an UoT students can already successfully participate in an

innovation process, but innovation process, but communication skillscommunication skills need to need to improve in order to become innovators / problem solvers.improve in order to become innovators / problem solvers.

• Is successfully done at UoTs, don’t publish too much too Is successfully done at UoTs, don’t publish too much too early.early.



Questions?

Dr. K. van Rijswijk

Aerosud ITC

012-662 5336

[email protected]