Sweden is one of five nations in the world manufacturing fighter aircrafts. Highly advanced technology is needed in order to develop a fighter aircraft. When developing advanced technology, new applications, other than those initially intended occur, spin-off. Some of Sweden’s largest companies are spin-offs from the fighter aircraft industry. Saab Automobile is an example of this. Spin-off as a concept appears in different contexts, from television series to audit terms but foremost in connection with splitting of companies. In the initial phase of our study we came across numerous definitions and concepts as explanation of spin-off and we therefore choose to adopt our own definition. Our study defines civil spin-offs from military aircraft projects. The Swedish aircraft industry consists of three large companies, Saab, Volvo Aero and Ericsson Microwave and we have for our case studies chosen spin-off processes within those companies. We interviewed persons well familiar with the above mentioned process in the respective companies, individually. The answers from the interviews, which we have analysed based on theory and literature, have enabled us to identify, describe and analyse factors promoting as well as counteracting spin-offs arising from military aircraft projects. From our study we have drawn the conclusion that all companies want to achieve spin-offs. One important way of creating opportunities for spin-offs is organising in cross functional groups, one of many internally acting factors that we have tried in our study. A factor that strongly counteracts the development of a spin-off is a strict focus on the core business of the company. This comes as a result of demand for saving measures, which has also led to much less time or no time at all for reflecting on new ideas. The historic role of the Swedish Government as a long term and demanding customer of military aircraft systems has over the last years shown less significance. The Government now has to play the role of co-operative link between the industry and the university in what is called a Triple Helix. The role of the Government is thus to support new enterprising as spin-off through technique parks, incubators and VINNOVA. Another significant factor supporting the development of spin-offs is co-operation in networks and clusters. In the spring of 2005 SwedCat was founded, a cluster between Saab, Volvo Aero and Ericsson microwave with the aim to take advantage of spin-offs from the respective companies and to support each other in developing them. We are of the opinion that this collaboration sets an excellent example for the industry, irrespective of line of business.

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<p>Volvo Aeros flygmotortillverkning i Trollhättan har infört ett antal nya detaljvarianter i produktionen. Detta har medfört att den robotcell som är avsedd att utföra en avgradningsoperation är i behov av uppdatering av både hårdvara och mjukvara. Denna rapport följer framtagningen av fixturkoncept som möjliggör att robotcellen kan användas även till de nya detaljerna. De förslag som arbetats fram sträcker sig från enklast möjliga till mer avancerade och nytänkande funktioner. Samtliga funktioner och koncept har genomgått gallringar i ett flertal steg. Förslagen har slutligen kombinerats och poängbedömts med konceptgenereringsverktyg till grund.</p><p>Efter en objektiv poängbedömning av sex olika koncept baserad på concept scoring visar sig två huvudgrupper med tre koncept i varje. Den ena gruppen bygger på en mer avancerad konstruktion med behov av två rotationsaxlar. Dessa medför ett flertal fördelar gällande effektivitet, men även påtagliga nackdelar vad gäller ekonomiska aspekter och idrifttagandetid. Den andra gruppen av koncept baseras mer på det befintliga fixturkonceptet. Detta medför fördelar gällande idrifttagandetid och kostnader.</p><p>Ett huvudkoncept som efter poängbedömningen visat sig mest lämpligt presenteras mer ingående och slutligen förs en diskussion gällande resultatets utfall samt rekommendationer till fortsatt arbete.</p> / <p>Volvo Aero’s aircraft engine manufacturing in Trollhättan has introduced a number of detail models into the production. As a consequence the robot cell dedicated to executing a deburring operation is in need of upgrading of both hardware and software. This report follows the development of fixture concepts that enables the robot cell to be used also for the new details. The proposals that have been developed range from the simplest to more advanced including novel functions. All the functions and concepts have gone through selection in multiple steps. The suggestions have finally been combined and evaluated with concept generation tools.</p><p>After an objective selection based on the concept scoring of six different concepts, the result can be divided into two main groups, each consisting of three concepts. The first group is a more advanced design with a need of two axes of rotation. These three concepts have several advantages when it comes to efficiency, but also obvious disadvantages when it comes to economy and production time. The second group of concepts is based on the fixture existing today. These three concepts are advantageous concerning production time and cost.</p><p>After the scoring process one main concept, judged to be the most suitable is presented more thoroughly. Finally the results as well as recommendations for continued work are discussed.</p>

Volvo Aeros flygmotortillverkning i Trollhättan har infört ett antal nya detaljvarianter i produktionen. Detta har medfört att den robotcell som är avsedd att utföra en avgradningsoperation är i behov av uppdatering av både hårdvara och mjukvara. Denna rapport följer framtagningen av fixturkoncept som möjliggör att robotcellen kan användas även till de nya detaljerna. De förslag som arbetats fram sträcker sig från enklast möjliga till mer avancerade och nytänkande funktioner. Samtliga funktioner och koncept har genomgått gallringar i ett flertal steg. Förslagen har slutligen kombinerats och poängbedömts med konceptgenereringsverktyg till grund. Efter en objektiv poängbedömning av sex olika koncept baserad på concept scoring visar sig två huvudgrupper med tre koncept i varje. Den ena gruppen bygger på en mer avancerad konstruktion med behov av två rotationsaxlar. Dessa medför ett flertal fördelar gällande effektivitet, men även påtagliga nackdelar vad gäller ekonomiska aspekter och idrifttagandetid. Den andra gruppen av koncept baseras mer på det befintliga fixturkonceptet. Detta medför fördelar gällande idrifttagandetid och kostnader. Ett huvudkoncept som efter poängbedömningen visat sig mest lämpligt presenteras mer ingående och slutligen förs en diskussion gällande resultatets utfall samt rekommendationer till fortsatt arbete. / Volvo Aero’s aircraft engine manufacturing in Trollhättan has introduced a number of detail models into the production. As a consequence the robot cell dedicated to executing a deburring operation is in need of upgrading of both hardware and software. This report follows the development of fixture concepts that enables the robot cell to be used also for the new details. The proposals that have been developed range from the simplest to more advanced including novel functions. All the functions and concepts have gone through selection in multiple steps. The suggestions have finally been combined and evaluated with concept generation tools. After an objective selection based on the concept scoring of six different concepts, the result can be divided into two main groups, each consisting of three concepts. The first group is a more advanced design with a need of two axes of rotation. These three concepts have several advantages when it comes to efficiency, but also obvious disadvantages when it comes to economy and production time. The second group of concepts is based on the fixture existing today. These three concepts are advantageous concerning production time and cost. After the scoring process one main concept, judged to be the most suitable is presented more thoroughly. Finally the results as well as recommendations for continued work are discussed.

Volvo Aero utvecklar, konstruerar, tillverkar och utför underhåll av motorer och tillhörande komponenter för civila och militära flygplan. Visionen är att leverera världsledande transportlösningar genom ständig förbättring och långsiktig utveckling av verksamheten, vilket för det dagliga arbetet innebär systematisk problemlösning genom metodiken praktisk problemlösning, vars ursprung är Toyota. Syftet med studien var att undersöka huruvida Volvo Aeros tillämpning av praktisk problemlösning var enkel, systematisk och vägledande, vilket ur Toyotas perspektiv ger förutsättning för effektiv problemlösning. Inledningsvis beskrevs Toyotas inställning och beteende till problemlösning utifrån The Toyota Way, som sedan följdes upp med en litteraturstudie gällande praktisk problemlösning. Vidare genomfördes en pilotstudie där Volvo Aeros tillämpning av praktisk problemlösning applicerades på ett organisatoriskt problem. Därefter utvärderades pilotstudien och förbättringsområden identifierades där metodiken var svår, otydlig och otillräckligt vägledande. Slutligen föreslogs följande förbättringar gällande Volvo Aeros tillämpning av praktisk problemlösning, vilka var vetenskapligt förankrade till Toyota. Definiering och analysering av symtomen ger förståelse för problemets orsaker. Kvantifiering av nuvarande tillstånd och det förväntades åskådliggör problemets omfattning. Framgår grundorsaken tydligt är sannolikt motåtgärden uppenbar. En god tillämpning av Plan-Do-Check-Act (PDCA) utgör ett effektivt och kraftfullt maskineri för ständig förbättring. Förbättringarna som föreslogs syftade till att förenkla Volvo Aeros metodik och ge användaren ökad trygghet och vägledning, vilket ger förutsättning för effektiv problemlösning som möjliggör daglig tillämpning och främjar ständig förbättring. / Volvo Aero develops, designs, manufactures and performs maintenance of engine and related components for civil and military aircrafts. The vision is to deliver world-leading transport solutions through continuous improvement and long term business deployment, which for the daily work means systematic problem solving through the methodology practical problem solving, whose origin is Toyota. The purpose of this thesis was to examine whether Volvo Aero’s approach of practical problem solving was simple, systematic and guided, which from Toyota’s point of view creates sound conditions for effective problem solving. Initially, Toyota’s attitude and behaviour towards problem solving was described from the point of view of The Toyota Way. Thereafter, a literature study on practical problem solving was completed. Furthermore, a pilot study was carried out where Volvo Aero’s approach to practical problem solving was applied to an organisational problem. The pilot study was evaluated and areas for improvements were identified where the methodology was difficult, indistinct and inadequate guided. Finally, improvements were proposed regarding Volvo Aero’s approach to practical problem solving, which was scientifically anchored to Toyota. Defining and analysing the symptoms brings understanding for the causes of the problem Quantifying the present condition and the expected illustrates the magnitude of the problem Appears the root cause to be clear is probably the countermeasure obvious A considerable approach using Plan-Do-Check-Act (PDCA) provides an effective and strong tool for continuous improvement The improvements were proposed with purpose to simplify Volvo Aero’s methodology and to support and guide the user, which creates sound conditions for effective problem solving and provides opportunities for daily use that foster continuous improvement.

<p>Major part of the current work describes the development of the update methodology for onedimensional code (TML) currently used at Volvo Aero Corporation during turbine design process. The methodology is then applied and tried out in a general engine analysis (GESTPAN).</p>

<p>This thesis work resulted in a template for how the thermal spray process can be controlled through robot programs. The robots today and their programs need to be replaced, therefore a new structure which can be matched with the new robot systems is needed. The work is limited to only concern structured programming on the new robots on Thermal Spray Centre (TC) with the programming language Rapid. The basic data for the program was retrieved from interviews with concerned personnel at TC, from studies on process parameters for thermal spray and from existing specifications at Volvo Aero Corporation (VAC). The thesis work briefly describes the process thermal spray and the four methods used at VAC. A literature survey on Jackson Structured Programming, Human Machine Interface and structured programming was made and used to compare, evaluate and suggest improvements for the thermal spray work cell. A functional suggestion for a menu system in a robot program for the thermal spray robot was presented. This will be in the robot permanently for uploading of detail programs from a network connected computer. An example of such a detail program was made but without robot movement and communication with the process computer. Testing of the programs has therefore only been made on a robot not suited for thermal spraying. The new detail program shows its parameters directly on the screen so they can be controlled against the operation papers. A programmer\2019s guide to the detail program has been made which is presented in the report.</p>

Major part of the current work describes the development of the update methodology for onedimensional code (TML) currently used at Volvo Aero Corporation during turbine design process. The methodology is then applied and tried out in a general engine analysis (GESTPAN).

This thesis work resulted in a template for how the thermal spray process can be controlled through robot programs. The robots today and their programs need to be replaced, therefore a new structure which can be matched with the new robot systems is needed. The work is limited to only concern structured programming on the new robots on Thermal Spray Centre (TC) with the programming language Rapid. The basic data for the program was retrieved from interviews with concerned personnel at TC, from studies on process parameters for thermal spray and from existing specifications at Volvo Aero Corporation (VAC). The thesis work briefly describes the process thermal spray and the four methods used at VAC. A literature survey on Jackson Structured Programming, Human Machine Interface and structured programming was made and used to compare, evaluate and suggest improvements for the thermal spray work cell. A functional suggestion for a menu system in a robot program for the thermal spray robot was presented. This will be in the robot permanently for uploading of detail programs from a network connected computer. An example of such a detail program was made but without robot movement and communication with the process computer. Testing of the programs has therefore only been made on a robot not suited for thermal spraying. The new detail program shows its parameters directly on the screen so they can be controlled against the operation papers. A programmer\2019s guide to the detail program has been made which is presented in the report.