A data-driven approach for a project management methodology for R&D Projects.

267 p.The thesis is based on the proposal of an R&D project management methodology based on the Earned Quality Method (EQM) and data analysis to improve the efficiency of R&D projects in a near-real production environment in a TRL 5 to 7. The thesis relies upon published papers that propose measuring and improving the management of R&D projects. The methodology leans on the formulation and gradual and recurrent evaluation of quality criteria as a performance indicator of the work carried out. The thesis stands on the concept that quality is a measurable quantity that accumulates throughout the project. The proposed project management methodology is built on three main aspects: Collaboration between the University and Industry; The correct interpretation of the TRL where research projects are developed; The study of different metrics for project management, such as the measurement of the success of projects, the KPIs of a project-based organisation, and the EQM. The methodology has been tested with three actual use cases with different characteristics in terms of project size, funding and team members; and validated on an R&D Centre in Advanced Manufacturing in Aeronautics. The pillars of the thesis are focused on the analysis of the mentioned components and their integration for the development of a methodology to improve the efficiency in the use of resources and the quality of obtained results in the R&D projects' framework. The key findings of these studies demonstrate the effectiveness of using quality criteria for measuring progress in the management of R&D projects, as well as providing a better understanding of several critical aspects of the realisation of these projects

Flexible Abrasive Tools for the Deburring and Finishing of Holes in Superalloys

Many manufacturing sectors require high surface finishing. After machining operations such as milling or drilling, undesirable burrs or insufficient edge finishing may be generated. For decades, many finishing processes have been on a handmade basis; this fact is accentuated when dealing with complex geometries especially for high value-added parts. In recent years, there has been a tendency towards trying to automate these kinds of processes as far as possible, with repeatability and time/money savings being the main purposes. Based on this idea, the aim of this work was to check new tools and strategies for finishing aeronautical parts, especially critical engine parts made from Inconel 718, a very ductile nickel alloy. Automating the edge finishing of chamfered holes is a complicated but very important goal. In this paper, flexible abrasive tools were used for this purpose. A complete study of different abrasive possibilities was carried out, mainly focusing on roughness analysis and the final edge results obtainedThe authors gratefully acknowledge the project “Estrategias avanzadas de definición de fresado en piezas rotativas integrales, con aseguramiento de requisito de fiabilidad y productividad IBRELIABLE” (DPI2016-74845-R), and “Discos de freno premium para trenes de alta velocidad”, by the Spanish Ministry of Economy

Project Success Criteria Evaluation for a Project-Based Organization and Its Stakeholders—A Q-Methodology Approach

The criteria that define project success change from one project to another, also from organization to organization, making success contextual for both the project organization and its stakeholders. This paper proposes a way to bridge this gap between what project success means to an organization and to its stakeholders in the context of Research and Development (R&D) projects. To achieve this, the available literature on project success has been analyzed to convert the different aspects identified into tangible units, allowing us to define and analyze the success criteria of a project in different dimensions. Subsequently, using Q-Methodology, which allowed us to determine among subjective opinions of Project Managers (PMs) of a project-based organization and their internal stakeholders, we will determine which criteria, within the previously identified dimensions, they consider as the most important for the success of a project, aiming to identify common success criteria that can be measured and controlled in the projects. Achieving the project goal, customer satisfaction regarding the quality of the activities, and knowledge generation turned out to be the most important criteria for PMs and stakeholders

Identification of Key Performance Indicators in Project-Based Organisations through the Lean Approach

For the time being, companies and organisations are being forced to compete in utterly complex and globalised environments, facing massive natural, economic, and technological challenges on a daily basis. Addressing these challenges would be impossible without a proper approach that helps them identify, measure, understand, and control the performance of their organisations. Lean principles and techniques rise as a solution. This paper justifies and proposes the use of lean principles and techniques to identify key performance indicators (KPIs) in project-based organisations based on their organisational and operational needs. The research focuses mainly on the identification and categorisation of KPIs through a qualitative approach, based on systematic literature review (SLR) of performance indicators, project management, and project success. As a case study, an analysis of relevant information of an R&D and innovation project-based organisation, such as quality manuals, a benchmarking process, internal studies, and surveys regarding what success means for different kinds of stakeholders and for the organisation itself was conducted. As a result, this research is of a high value for project-based organisations, especially those that are not apprised of how to correctly formulate a series of KPIs, or whose path to it is still not clear.Authors are grateful to Basque government group IT IT1337-19 and the Spanish Ministry of Science Mineco REF DPI2016-74845-R and project PID2019-109340RB-I00

Advanced Manufacturing Centres, Practical Model to Boost Technology Transfer in Manufacturing

Establishing collaboration strategies with interdisciplinary networks in research is a crucial success factor for the companies in any sector, especially in manufacturing for aeronautics. In the aeronautical supply chain, Small and Medium-sized Enterprises (SMEs) lack of these types of alliances with universities and other research institutions, which could give them access to shared and specialized knowledge, may strictly limit those companies to learning from their own experience. One way to break this dynamic for industrial companies is to be an active part of research, development, and innovation centres. In this paper, a study to create new advanced manufacturing centres is presented, centres whose activities are focused on Technology Readiness Levels (TRL) 5-7. The approach is based on a project management methodology, and it is applied to the aeronautical sector in the Basque Country. An initial study of the international experience and state of the art in this type of facility, as well as an analysis of the current socioeconomic environment of the Basque Country are presented. A benchmark study was done to identify the key processes that this centre must promote for this initiative to succeed, or those areas of knowledge that can make or break the initiative. Finally, the results showed a definitive picture for establishing an advanced manufacturing centre in the Basque Country. This work lays both the foundations of knowledge in the sector and the difficulties noted, so it can serve as guidance for similar initiatives.We thanks the strong support to the centre of the Basque Government (Dept of Economic development and infrastructures and SPRI) and Council of the Province of Biscay, Technological park of Zamudio and University of the Basque Country. Special thanks to Eng. Alfredo Lopez-Diez for the ideas and daily efforts to develop the centre model along with ITP Aero, Danobat Group and the other 76 company partners. Thanks are due to Joserra Otegi from UPV/EHU and funds from Excellence groups of the Basque university system no. IT1337-19 (from Basque Government). Centre CFAA can be looked up at: https://www.ehu.eus/en/web/CFAA/hom

Early detection of tool wear in electromechanical broaching machines by monitoring main stroke servomotors

This paper aims to provide researchers and engineers with evidence that sensorless machine variable monitoring can achieve tool wear monitoring in broaching in real production environments, reducing production errors, enhancing product quality, and facilitating zero-defect manufacturing. Additionally, broaching plays a crucial role in improving the quality of manufacturing products and processes. These aspects are especially pertinent in aeronautical manufacturing, which serves as the experimental case in this study. The research presents findings that establish a correlation between the variables of a broaching machine’s servomotors and the condition of the broaching tools. The authors propose an effective method for measuring broaching tool wear without external sensors and provide a detailed explanation of the methodology, enabling reproducibility of similar results. The results stem from three trials conducted on an electromechanical vertical broaching machine, utilizing cemented carbide grade broaching tools to broach a superalloy Inconel 718 test piece. The machine data collected facilitated the training of a set of machine learning models, accurately estimating tool wear on the broaches. Each model demonstrates high predictive accuracy, with a coefficient of determination surpassing 0.9.Thanks are addressed to MCIN/AEI/10.13039/501100011033/and European Union NextGenerationEU/ PRTR” - Proyectos de Transición Ecológica y Transición Digital , Quolink: A new way to assess quality in manufacturing processes by merging process data in high connected production systems in aeroturbines, Ref TED2021-130044B-I00. Thanks are also addressed to Basque, Spain for the support of University research groups, grant IT1573-22. Thanks are also due to European commission by H2020 project n. 958357, and it is an initiative of the Factories-of-the-Future (FoF) Public Private Partnership, project InterQ Interlinked Process, Product and Data Quality Framework for Zero-Defects Manufacturing. Results were analyzed by models developed in Project KK-2022/0065 Lanverso and Hatasu. This work was also partially supported by the Spanish Ministerio de Asuntos Económicos y Transformación Digital and the European Union NextGenerationEU through the project LocoForge: Mimbres instantiation for railways and Industry 5.0 vertical sectors (grant TSI-063000- 2021-47), funded by the Plan for Recovery, Transformation and Resilience