Software helps transition from traditional to light-weight material

The two largest commercial jet manufacturers highlighted the emerging trend when they debuted the Boeing 787 Dreamliner and Airbus A350 XWB, showcasing the first commercial jets to be made primarily with lightweight carbon composites.

They’re the first. They won’t be the last. The industry is making a concentrated push toward lighter, more fuel-efficient, and more durable materials. Aircraft composed of composite components address these targets.

Switching to the new materials isn’t easy. The innovation and redesign required can bring production challenges, says Rick Gallisa, industry director of aerospace and defense for Dassault Systèmes. Metallurgic manufacturing has been understood for years, making the process predictable, if not easy. Composite technology, on the other hand, is evolving, Gallisa says.

“Not just the materials, but the specific processes in manufacturing, which truly impacts the integrity of materials and components,” he explains. “The complexities and interrelated nuances during manufacturing steps must be analyzed closely.”

Easier said than done.

DELMIA Apriso software offers manufacturers a way to streamline their transition from traditional materials to carbon composite materials by managing complex production, quality, maintenance, material synchronization processes, and maitenance issues.
 

Complex production
Built with a business process management (BPM) architecture, the software allows customers to manage levels of complexity, including extended and multi-level bills of material. It also captures unique intellectual property within the processes that manufacturers can use to differentiate themselves. The software does not require customization, so business managers do not have to rely on their IT staff to improve it.
 

Quality assurance
The quality solution from Dassault, who acquired Apriso in 2013, compiles more than three years’ worth of previously-released applications.

“Apriso applications provide quality planning, execution, SPC, and other capabilities while working in conjunction with enterprise resource planning (ERP) to execute quality assurance/quality control (QA/QC) from raw material or component inspection and siposition, through work-in-progress (WIP) and final assembly,” Gallisa explains. He adds these capabilities provide feedback loops to engineering to help scale up new product introductions.
 

Material synchronization
The manufacturing execution systems has a robust warehouse application that can function on its own, or in conjunction with ERP, Gallisa says. “This allows us detailed knowledge of the locations and disposition of components prior to accepting an order to make something, avoiding the commonly found scenario where only 17 of 19 components are readily available for use, and time is wasted compiling an incomplete bill of materials.”
 

Maintenance issues
DELMIA Apriso maintenance can function by itself, in conjunction with ERP, or as part of a complete Apriso solution. Manufacturers will know the readiness and calibration of tools and equipment to align orders against, and an ongoing monitoring of overall equipment effectiveness (OEE) and key performance indicators (KPIs).

Working with customers

Dassault works closely with its buyers before launching products, Gallisa says. Many items in the company’s catalog are based on customer feedback regarding specific problems they have encountered. Gallisa says the close relationship between client and retailer benefits both.

“They have a solution to fit specific challenges,” he says, “and we have greater confidence our solutions will be valued in the marketplace.”

Gallisa goes on to explain that Dassault evaluates each customer on an individual basis, saying that each has unique operations. Dassault evaluates each manufacturer’s intellectual properties and customizes its software based on those needs.

After the software is installed, Apriso offers various support packages, including 24/7 support across the globe. Software training courses are offered worldwide, including in Long Beach, Calif.; Paris; and Krakow, Poland. Customized training is also available at customer locations.

Dassault Systèmes
www.3ds.com
IMTS 2014 Booth #E-3125