Lean Aerospace Initiative
S70A Derivative Helicopters
March 31- April 1, 1998
Presented By:
Chris Holmes, Team Leader - Development Operations
Sikorsky Aircraft Corporation
LEAN AEROSPACE
INITIATIVE
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Overview
Define system architecture
– Air vehicle as a system
– Focus on platform approach
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Relation to helicopters
Hypothesis
– Architecture should not be static
– Architecture places limits on flexibility
– Architecturally driven configuration vs. market driven
configuration
FG033198-2 ©1998 Massachusetts Institute of Technology
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INITIATIVE
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Why Platform Perspective?
Air vehicle service lives over twenty years
Churn in installed technologies
Reconfiguration of mission
Emergence of zero-time and SLEP programs
Expansion of product line
FG033198-3 ©1998 Massachusetts Institute of Technology
LEAN AEROSPACE
INITIATIVE
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Definitions
Architecture
– “..the scheme by which the functional elements of a
product are arranged into physical chunks and by which
the chunks interact.” Ulrich & Eppinger
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Configuration
– “..the specific mix of systems and sub-systems as
defined by the customer” Holmes
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Platform
– “..a design from which a host of derivative products can
be effectively and efficiently created” Meyer & Lehnerd
– Note difference in context from military application
FG033198-4 ©1998 Massachusetts Institute of Technology
LEAN AEROSPACE
INITIATIVE
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Discussion Points
History
Design architecture
Market forces
Warning signs
Reaction
Today
Tomorrow
Summary
FG033198-5 ©1998 Massachusetts Institute of Technology
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INITIATIVE
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S70A History
History
– Emerged from UTTAS competition
– UH-1 replacement
– Performance / Capabilities
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High / Hot
Ballistic survivability
19 combat equipped troops
Reliability
Air transportability
– Ink on mylar design
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LEAN AEROSPACE
INITIATIVE
S70A Lineage
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INITIATIVE
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S70A Architecture
Sold to DOD as a “platform”
Multiple mission capability
Reliability and ruggedness
“Jeep with a rotor head”
Organization mapped to architecture
Air Vehicle
Airframe
Design
Tub
Penetrations
Avionics
Design
Electrical
Design
Propulsion
Design
Mission
Systems
Harness
Routing
FG033198-8 ©1998 Massachusetts Institute of Technology
LEAN AEROSPACE
INITIATIVE
The Result
Static Architecture / Static Demands
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INITIATIVE
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S70A Market Forces
Declining DOD market
Proven reliability
Established logistics chain
Changing technology
S-70 Sales (masked)
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Aircraft Sold
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30
25
20
15
10
5
0
1975
1980
1985
1990
1995
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LEAN AEROSPACE
INITIATIVE
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Severity of modifications
Effect on system elements
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Warning Signs
Electrical power
Weight and balance
Airframe structure
Cabin volume
Effect on organization
– Configuration of design team
– Skill sets
– Quantity ↓ vs. Quality ↑
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Time to market
– Basic vehicle + modifications = Basic vehicle timeframe
FG033198-11 ©1998 Massachusetts Institute of Technology
LEAN AEROSPACE
INITIATIVE
The Result rev A
Static Architecture / Dynamic Demands
FG033198-12 ©1998 Massachusetts Institute of Technology
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INITIATIVE
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Project ‘X’
SAR mission
– Fuel system
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Extended range over water
– Floatation
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Extensive mission equipment
– SAR boards
– Incubators
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Sophisticated avionics
– Search radar
– FLIR
– Weather radar
FG033198-13 ©1998 Massachusetts Institute of Technology
LEAN AEROSPACE
INITIATIVE
Helicopter Manufacture
Options
Development
Operations
Hangar
Major Assy
Final
Assembly
FG033198-14 ©1998 Massachusetts Institute of Technology
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INITIATIVE
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Reaction
Platform abandonment
– What is upper limit?
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Knowledge capture
– A/C program to A/C program
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Channeling of personnel
– Development vs. Production
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Organizational “concern”
– Partitioning of two distinct businesses
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Chasing market requirements
– Marketing requirements to engineering
FG033198-15 ©1998 Massachusetts Institute of Technology
LEAN AEROSPACE
INITIATIVE
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Today
Development Operations Teams
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Design / planning
Operations
Hangar operations
Dedicated team leader
– Safety, Compliance, Cost, Schedule
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“Systems” design approach
Return of sale focus
Customer understanding
Throughput
FG033198-16 ©1998 Massachusetts Institute of Technology
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INITIATIVE
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Platform Teams
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Tomorrow
Full Model View
Platform team leader
Team leader for each program
Steady pool of personnel
Transfer of Information
S92
– Platforms
– Multinational
– Systems expansion
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INITIATIVE
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Summary
Platform architecture
– Infusion of new technology
– Efficient platform modification
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Limits determined during initial design
Long term view
Knowledge capture
Business expansion
Time to market
Cost, cost, and did I say cost?
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