The aerospace industry is currently faced with the development of new efficient turbofan engines, focused on fuel burn reduction combined with an additional decrease in noise emission. The upcoming engine programs and their components require new approaches regarding product materials, product design, engineering as well as challenging demands on supplier und supply chain processes.

Based on the development of these new efficient turbofan engines, also the manufacturing process of the new programs also had to be considered within the integrated clean sky approach. The major changes of the new products and product structures required that the high level strategy of manufacturing new turbofan engines and components had to be reviewed as well as the specific production concept on the shop floor.

The production had to fulfil the future requirements of integrating new production technologies, shortening product life-time cycles, achieving target costs of manufacturing and decreasing lead time as well as increasing quality demands. Additionally, the production encountered within volatile environment with fasten changing constrains and parameters regarding production volumes, product design changes and new technology processes.

Currently, engines and parts manufactures are mainly based on widespread manufacturing strategies and conventional production concepts. Based on general competences for production/logistics systems, the specific knowledge for the production processes within the aircraft industry as well as for the development of methodologies ifp consulting established a specific methodology.

Beginning with the definition of the methodology approach and a detailed analysis of existing requirements, concepts and targets, built up a methodology structured by different detailed levels of an integrated production concept. The methodology itself had to fulfil the requirements of a robust, sustainable, systematic, repeatable and efficient proceeding.