Machining of jet engine turbine disks
Inaugurated in 1987, the Le Creusot plant is a real technological showcase for Snecma. The plant is dedicated to the machining of turbine disks, one of the most critical parts in aircraft engines.
The plant’s industrial organization is unique, since it operates around an entirely automated workshop, including 16 numerically controlled machines (vertical lathes, milling/jig-boring machines, measuring robots, automated warehouses, etc.). This high-tech facility, the only one of its kind in Europe, turns out nearly 400 turbine disks a month, including more than 20 different types.
Le Creusot’s workshops, offices and technical installations cover a total area of 13,000 square meters (140,400 sq ft), and employ about 200 people. Working in such a technologically advanced environment, plant employees must constantly update their knowledge and skills.
The site is also a symbol of the rejuvenation of the “Plaine des Riaux”, an industrial region which was once the cradle of the industrial revolution in Burgundy, a region that has been dedicated to the metallurgical and mechanical engineering industries since the early 19th century. The Snecma plant, located near the cultural center and university, is heavily involved in local life. For example, it has signed twinning programs with local schools, to offer internships to future technicians and engineers. It is also involved in various corporate patronage programs, such as contributing to the construction of a twin-seat aircraft by the technical college of Le Creusot.
Expertise
Aircraft engines must be manufactured to very strict quality requirements.
The turbine disk is a major component, and any in-service failure is obviously unacceptable for safety reasons. A computer system must therefore guarantee the traceability of each part at every step in the machining process. Moreover, in service these parts are subject to severe stress. They must withstand very high rotation speeds and temperatures, and a centrifugal force exceeding a ton. The production of these parts therefore demands all of Snecma’s technical expertise, as reflected in the skilled personnel and state-of-the-art resources at Le Creusot. By constantly upgrading its technology and organization, Le Creusot can now machine a turbine disk in just four weeks, a task that used to take six months.
Turbine disks are made of a very high strength alloy to stand up to extreme operating conditions, and are therefore particularly hard to machine. Furthermore, these disks, measuring 592 to 912 mm in diameter, must be machined to tolerances of just 1/100 of a millimeter. The teams at Le Creusot therefore work with special machining and cutting tools that are particularly robust and precise.
The flexible automated workshop is the site’s major asset. Wire-guided trolleys pass in silence from one station to another, while the central computer manages the programs that fully automate all processes. Computers are everywhere, and the plant is surprisingly silent.
Major time savings have also been achieved by eliminating malfunctions and using "just in time" inventory management; i.e., significantly reducing production cycles and inventories by delivering products to customers "just in time".
Shorter cycles, quick reactions, smaller inventories and reduced production costs combine to make Le Creusot an integral part of Snecma’s drive for enhanced market competitiveness.
Safety / Environment
Industrial safety and environmental protection are essential concerns at Le Creusot. Meeting these requirements depends on a combination of current regulatory certifications and continuous improvement measures.
In 1995, the Le Creusot site won the regional prize for environmental innovation. It received ISO 14001 certification in 2000.
Snecma Le Creusot
Plaine des Riaux - Avenue de l’Europe
BP 97
71203 Le Creusot Cedex
France
Phone: +33 (0) 3 85 77 77 12
Fax: +33 (0) 3 85 77 77 77
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