Circular economy - PowerPoint Presentation

Slide1

Circular economy

An MRO scenario

Brussels, 29-30 November 2016

Speaker:

Angelo Corallo Slide2

Introducton – cPDM Research Lab Università del SalentoSlide3

Introduction - Avio Aero a GE Aviation BusinessSlide4

MRO in Avio Aero: overview

Avio Aero performs MRO activities at the facility in

Brindisi

in Italy.

MRO

(Maintenance, Repair and Overhaul)

for the Italian Air Force, the Brazilian Air Force and the Royal Netherlands Air Force

on best-in-class solutions

CRO

(Component Repair and Overhaul)

on

AvioAero

designed components for the for the

GEnx

, GE90, Trent900 and V2500 aircraft engines

In November 2014 the Brindisi plant began overhaul and maintenance operations on LM family engines installed on large ships and in industrial facilities or used for energy production. Many of the turbines arrive from GE Power & Water facilities and from customers worldwide.

Source: www.avioaero.com

Source: www.geaviation.comSlide5

Brindisi MRO operations

GATE 0 - PLANNING & ENGINE ARRIVAL

The work is planned and scheduled as commissioned by the customer;

T

he engine arrives at the

Brindisi

facility inside an enormous container, which is also checked.

GATE 1 - DISASSEMBLY & INSPECTION

In a hall adjacent to the building where the engine overhaul work is performed, the container is disassembled and opened using a series of lift trucks and cranes;

the

engine is lifted out from inside and taken to the overhaul area for the initial visual inspection, cleaning, non-destructive testing (e.g. liquid penetrants, ultrasound, thermal imaging and magnetic checks); finally the engine undergoes a technical inspection.

GATE 2 - PROCUREMENT, REPAIR & KITTING

The materials required for the activities are procured (from bolts to spare parts and small components), the suppliers are monitored and the necessary repairs made. In the kitting stage the serviced parts are prepared for reassembly.

GATE 3 – ASSEMBLY

Each part or component disassembled during overhaul or maintenance is reassembled, the engine is balanced and all relevant parts ground ready for the strict final testing stage.

GATE 4 - TEST & CUSTOMER RELEASE

The

engine

is started, tested and then returned to its container to be shipped and returned to service at sea or for energy generation

FOCUS

Gate

1-2: RepairSlide6

Gate 1-2: Repair<< Simplified processes>>

Scraps

are set aside,

waiting for the client to take them

Outsourced

Repair

Parts

are

send

to

suppliers

Repair

in-

house

parts start the repair cycle on premise Efficient parts are taken to the kitting area Slide7

Repair Distinctive Technologies

Component Repair Capabilities Machining (V/H turning, V/H Reamer)

Welding (TIG, micro plasma, resistance welding, vacuum titanium chamber)ESD (Electro Spark Deposition)

BrazingGrinding/Tip GrindingsHi Pressure water jet stripping

Sand blasting

Plasma/Thermal SprayThermal spray monitoring system (

Accuraspray

)

HVOF (Hyper Velocity Oxygen Fuel)

Shot/Glass peening

Painting

EDM (Electro Discharge Machining)

Heat Treatment vacuum and air Furnace

Super-PolishingSlide8

AvioAero MRO information management

During the inspection phase disassembled parts are labeled with a ticket that represents the status of the parts: red for scrap, yellow for efficient and green for parts headed to repair

To each part to be repaired is associated a work order containing the sequence of the repair operations the part needs to undergo

.

Different IT systems support the MRO process:

BPM

MOS

TARANTA

Rfid

management application designed under national R&D Project SPIA (currently under development)

Legacy system, manages all the information related to engines, parts and work orders

System designed to monitor and improve company’s processes

Slide9

Avio Aero MRO as-is CE scenario

MRO

Closed loop MRO System

Image: adapted by Nasr

, N . and Thurston, M. (2006).

Remanufacturing: A Key Enabler to Sustainable Product Systems. Rochester Institute of Technology

AvioAero

works on entire engines as well as on individual components

.

After

the maintenance, undergone in compliance with the highest standards,

the engines can have a second new life

.

Spare

components can be reconditioned as well, as single items.

Parts and whole engines are reconditioned and given back to the owner client, no swap is allowed among different clients.Slide10

Towards the circular economy Avio Aero Improvement Goals:

Additive repair

Lean Thinking for

CE

Layout Optimization

Visual

management,

Digital Repair Work order

managementSlide11

Additive

technologiesAdditive manufacturing: the industrial version of

3-D printing

Healthcare, prosthesis and medical implants

Nanoprinting

Rapid prototyping

Mass-production of a critical metal-alloy part to

be

used

in

aircraft engines (

Avio

Aero technologies

)

Direct Metal Laser Sintering (DMLS) Electron Beam Melting (EBM)

CLOSING THE LOOP. During

repair, maintenance and remanufacturing, a make to-order model can be applied to minimise inventory waste as spare

parts can be produced locally only when needed

,

with lower energy

intensity processes

.

This is even more the case with modular and upgradable components. Products can be maintained in-situ using Additive Manufacturing repair technology, thereby maximising their use and extending their lifespan.

Source: www.avioaero.comSource: www.avioaero.comSource: www.avioaero.comSlide12

Additive RepairTowards the conventional production of components with a high amount of cutting processes,

Additive Manufacturing processes construct the components layerwise, even in repair

operations.However, a holistic integration in the MRO processes is not yet researched.

The

production of the

bladed disks (‘

blisks

’)

used in aero engines has a high environmental impact, with significant material waste.

Early

demonstrators showed that

Additive Manufacturing

can be used to manufacture and

maintain

the

blisks and reduce waste with ~60% material savings and ~30% time savings. Additive Manufacturing can also be used for the in-situ repair of damaged blisks and thereby extend their operational life. ENVIRONMENTAL AND COST ADVANTAGESStorage costs cutCost related only to raw materials supply instead of parts shippingLess Environmental cost of transport

No waste on materials

Fields of application

Engine bladed disks

Landing gears

Spare partsSlide13

Lean Thinking for Circular Economy

Waste is what is waste for the Client

Looks

at waste as what can

not be re-introduced in the economy (

thus, is waste

for the

environment

)

Lean

could

be

a

complementary tool in circular economy

scenarios and Lean thinking the business model for the implementation of Circular EconomyCircular

…from two different, but close, points of view.

Lean and

Circular

share the

same

target,

which

is elimination of

waste… Slide14

Lean MRO initiatives

MRO facility layout optimization

Reconfiguring workspace layout to reduce wasted movement of parts, people, and information

Repair Process oriented layout

Visual Management

An effective visual communication system can help manufacturing employees eliminate significant waste

Digital Repair work order management

Implementing a system to manage repair information (planning, work instruction details,

kpi

, etc

.)

Finite capacity scheduling Slide15

Expected Benefits Lean MRORealistic and feasible delivery promises

Reduced delays in delivery of repair partsEffective management of labour

resourcesReduction in overtime.

Visibility of information, scenario analysis, for example what-if analyses of the impact in resource availability and customer demandsLess time spent on planning activities

The benefits are better visible medium

to long term,

when the organization will have fully embraced the changeSlide16

Investments and expected results10

% increased in-service efficiency through

extension of

components life+20% energy

saved

Investments

H2020 funds

Italian

PON (

MiSE

. MIUR)

Apulia

Regional

funds

Expected

resultsSlide17

Contact

Angelo Corallo:

angelo.corallo@unisalento.it

https://cpdm.unisalento.it

Thanks for your attention