Additive manufacturing ALSTOM REX at ENSAM conference "A new BIG BANG" - 27th of November 15 - Paris

1. Christophe ESCHENBRENNER
DIGITAL SUPPLY CHAIN & CUSTOMER SERVICE MANAGER
15/10/2015
3D Printing
The 3rd industrial revolution is underway!

2. © ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is
complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to
change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Presentation title - 30/11/2015 – P 2
Alstom Transport
Four activities
TRAINS INFRA & SYSTEMS
SERVICES SIGNALING

3. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 3
Supply chain paradigm
DIGITAL HELPS BALANCING THIS CHALLENGE
MISSING PART SITUATION OVER STOCK
Production stopped, train in depot Obsolescence, Cash mobilized

4. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 4
Definition of ADDITIVE MANUFACTURING
(preferred term in industrial activities vs 3D Printing)
TECHNOLOGY
A process that allows to
manufacture layer by layer
by adding material from a digital
design
MATERIAL AVAILABLE
Polymer (ABS, Polyamide, …)
Metal (steel, aluminium, titanium…)
Others (Ceramic, …)
Source: EOS

5. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 5
Why is Supply chain concerned by 3D Printing ?
A disruption is identified…

6. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 6
No inventory Customized Localized Quick to deploy
… changing the way business is done…
Creating a very collaborative supply chain

7. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 7
…and bringing new challenges
7
Protection ? Quality ?
FAKE REAL
Master data? Optimization ? Make or buy ?
Value ?

8. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 8
Additive manufacturing for Railway
4 major use cases
RAPID PROTOTYPING
- R&D validation
- Reverse engineering
- Integration & tests
 On-demand (5 days)
IP
QUALITY
DIRECT MANUFACTURING
- Replication
- New design
- Tools, Jigs
 1 to 50 batches
 Complex parts
INDIRECT MANUFACTURING
(TOOLING FOR PRODUCTION)
- Moulds
- Patterns
 10 to 100 batches
 Fixed costs killer
Mature market Mid-mature market
Immature market
DIRECT REPAIR
- Repairs
 R&D
Immature market
QUALITY

9. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 9
Gartner Hype cycle / 3D
ASTER shared vision
Timing ?
What Gartner’s analyst says
Source:
Gartner 07/2014

10. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 10
Global Market trend:
New players and business models emerging
Emerging Marketplaces 3D Printer farms

11. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 11
Automotive benchmark
80% of this Peugeot « Fractal » prototype built by a 3D Printer
Source:
Peugeot 2015

12. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 12
Alstom strategy:
Let’s go, on the right track !
US ITALY SPAIN UK
 FABLAB with CETIM (VIDEO)

13. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 13
Rapid prototyping application
Supporting R&D
Accelerate innovation, reinforce customer intimacy
A « Surverse » created by our Toilet Center Interiors implementation moke up

14. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 14
Rapid prototyping application
Integration and test usage
Bogie for a tram train – Le Creusot

15. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 15
Rapid prototyping application
Services solutions
Help to fix issues, contribute to reverse engineering
Windows demisting solution Spares reverse engineering

16. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 16
Direct manufacturing application
Services solutions
MODERNIZATION PROJECT (UK)
 AIR VENT: 1 part replaces 11 assembled one
 Polyamide flame retardant
 50 parts manufactured
KEY BENEFITS
 Reduce lead time
 Fine for small series
 On-demand after sales
NOW INCLUDED IN OUR OBSOLESCENCE SOLUTIONS
Make by 3TRPD

17. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 17
Roadmap
Adressing metal parts
Topological optimization to leverage technology benefits
Connecting rod
Make by CETIM

18. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 18
Direct manufacturing application
Substitution of metal parts
Replication of obsolete parts unavailable on the market
3 teeths gear
Make: CETIM

19. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 19
Facts and Current limitations
 Intellectual Property
• Check freedom to operate the spare. IP Rights linked to the spare ?
• Don’t infringe Patents, Design or Copyrights of Third Parties
 Design
• Scarce talent
• Change management (acceptation, learning), Design rules (norms, softwares).
 Technical performances and costs (rapidly evolving)
• Technology not suitable for mass production (sustaining limitation)
• Build speed, Parts size, finishing
• 3D printers price and productivity, Price of powders
 Quality and safety
• Norms to be defined in industries
• Certification of safety critical parts

20. © ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ALSTOM - 30/11/2015 – P 20
Organization
design, manufacturing, sourcing and supply chain are impacted
 Agility: a product might be manufactured in different way along its life cycle
 A new eco-system to build: Research, Talent, supplier development, …
 Taking into consideration future progress in the next decades.
R&D Model Prototype /
Pre-serial
Serial After-sales
Volume
Time

21. © ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is
complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to
change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Presentation title - 30/11/2015 – P 21
YES, additive manufacturing is entering workshops… for certain parts !
Conclusion

22. Contact:
Christophe ESCHENBRENNER
DIGITAL SUPPLY CHAIN & CUSTOMER SERVICE MANAGER
+33 6 71 92 20 41
christophe.eschenbrenner@transport.alstom.com
Questions…?

23. www.alstom.com