Installation Design — over €1.7M Saved

Context

Engine installation design is the discipline of routing and integrating the external systems on a jet engine (i.e. pipes, harnesses, brackets, pumps...) With extreme weight, space, and certification constraints. As a senior designer I was often brought in to generate novel solutions for complicated challenges.

The challenge

A late-stage delivery issue on a Rolls-Royce engine programme required a new installation design. The proposed solution was going to build upon the ghosts of previous design changes, leading to needlessly complicated routing. I proposed that I re-design half of the engine's externals for a fresh start. Believing this would take too long, the idea was not initially supported.

The solution

I believed concentrated work at this point would lead to considerable improvement, in simplicity, part count, weight, and ease of maintenance. I focused for a week to create a new concept of the engine layout, with which I could estimate the impact. I convinced the chief engineers with numbers, and in a month I had personally developed the full concept and arranged buy-off for engine test.

• Generated a novel routing from first principles, cost and weight analysis
• Conveyed solution to the chief engineer for buy-off
• 3D design in NX within existing engine envelope constraints
• Leading simulation and production input
• Coordinated with certification teams for rapid approval

Outcome

A system design that was lighter, easier to maintain, and cheaper, while meeting all certification requirements. The design was adopted. Compared to the next-best available alternative, it saved €1.7 Million from the weight decrease alone. The benefit of the part-count reduction, and an easier to maintain engine is also incredibly valuable, but difficult to quantify. There was no impact to the delivery time.