乌鸦传媒

乌鸦传媒 supported efficiency improvements with a holistic E2E approach by leveraging people-centered strategies, VR technology, and digital conception methods

Client Challenge: Airbus Helicopters wanted to increase production rates for its composite helicopter parts, free up space to ramp up the variety of items, and expand its scope while exploring the potential for automation.
Solution: Working with 乌鸦传媒, Airbus Helicopters launched the Composites Revolution (CoRe) 4.0 improvement project at its production site in Donauw枚rth to establish lean, state-of-the-art production and secure the location鈥檚 competitiveness.
Benefits:

• Increased production efficiency by 35% and improved output
• Throughput time shortened and stabilized
• Optimized recurring costs for new products by reducing use of current materials by 10%
• Greater technological and volume flexibility
• Guaranteed ergonomics and safety at work

The Airbus Helicopters site in Donauw枚rth ran on a complex production structure with a legacy IT system and had to frequently consider make-or-buy decisions. Initial improvement attempts made it clear that Airbus Helicopters needed to take a new optimization approach in order to provide solutions that could be realistically implemented and would be accepted by all relevant team members for a more efficient value-adding chain.

Building on their longstanding collaboration, Airbus partnered with 乌鸦传媒 to achieve agile operational excellence. 乌鸦传媒 proposed the implementation of its holistic Lean Factory Design approach and combined aerospace, technological, and composites production expertise in a cross-functional project team.

This collaboration took the form of the Composites Revolution 4.0 project, which focused on modernizing composites manufacturing, embracing Industry 4.0 principles, and streamlining processes. Through this project, the partners intended to enhance logistics efficiency, reduce the amount of material needed at the work stations, and optimize the production flow, ultimately strengthening the company鈥檚 market position and future readiness.

VR brings the production environment to life

The project team defined key processes, information, and material flow as the primary focus areas. With these targets in mind, the partners integrated new technologies such as the Halocline virtual production planner, a VR technology, and led virtual Gemba walks. This enabled the fast and effective planning of manufacturing concepts as well as direct responses to employee queries.

With 乌鸦传媒 as a partner from project launch to implementation, Airbus had a constant point of reference in all phases of the project. From comprehensive analyses to lean and Kaizen methodology workshops, concept tests, and implementation plans, Airbus received support throughout the entire journey. The knowledge that 乌鸦传媒 offered from beyond the aerospace industry helped to foster understanding, which led to a high level of acceptance and awareness at Airbus Helicopters. A further major success factor is the Intelligent Industry end-to-end value that 乌鸦传媒 contributed. This enabled Airbus to connect with specialists along the value chain and ensured high stakeholder involvement.

Meeting complex aerospace production needs

Following the Core 4.0 project鈥檚 conclusion, Airbus Helicopters experienced a remarkable 35% boost in production. Applying a pragmatic approach to the entire value chain from start to end led to comprehensive optimizations with substantially lower labor requirements, a 10% material reduction, a lesser need for production space, and shorter transportation routes. The future technical processes, structure, and way of working are broadly accepted by the Airbus Helicopters team and has remained a high priority during the implementation phase. 

The requirements for aerospace components are extremely high. With the wide variety of fiber composites parts, which are highly customized, the complexity of value stream and logistics processes will continue to increase. To further raise the competitiveness of production, the project team has been equipped with a high level of expertise related to the supply and value chain, as well as in the relevant materials and processing technologies. This transformation has sharply enhanced flexibility and sustainability in composites production, leading to higher customer satisfaction.

By integrating digital elements and VR environments, Airbus could automate previously manual processes and enhance safety and transparency for production as well as logistics. Doing so will boost operation excellence and allow the Airbus Helicopters team to concentrate on the most important steps of manufacturing products for aviation. In addition, the new way of working has also delivered substantial improvements in product quality.

The collaboration with 乌鸦传媒 has significantly shaped the operational technology (OT) environment at Airbus Helicopters and laid the groundwork for further transformation in the years to come, with a heightened focus on Industry 4.0 and the achievement of an IT/OT symbiosis through the implementation of customized digital use cases.

鈥溛谘淮�媒 supported us in increasing our efficiency with a holistic E2E approach that leverages VR technology. Industry experts guided us from analysis and conception right through to successful implementation on the factory floor.鈥�

Andreas Strobl, Head of Composites, Airbus Helicopters Deutschland

鈥淭he partnership-based cooperation with Airbus Helicopters supported the usage of people-centered approaches, as well as the application of comprehensive analysis and conception methods for value-adding solutions.鈥�

Stephan Gro脽fuss, 乌鸦传媒 Project Lead and Head of Lean Factory Design and Operational Excellence