NCMS Project #: 142255
Problem: Utilizing legacy part design/manufacturing/assembly methods has translated to slower than desired component replacement rates on a number of legacy airframes, the T-38 wing in particular. Parts manufactured using legacy manufacturing processes add additional risk as the supply chain is less robust and the lead times on components can be significantly longer.
Benefit: A wide array of maintenance organizations and stakeholders who are tasked with designing and maintaining aircraft can benefit from the best practices learned from this initiative. Demonstrating the importance of designing for manufacturability will help maintainers in both the DOD and in the commercial industry streamline their assembly processes.
Solution/Approach: The project will utilize the Design for Manufacture and Assembly (DfMA) design approach, focused on optimizing the design to reduce manufacturing and assembly time to increase production rate. A full-size hole determinant assembly process will be employed to decrease assembly time by utilizing the part’s features to locate the part on the assembly without the need for additional tooling and holding fixtures for alignment and removing the need to drill full-sized holes at the time of assembly. The goal is to increase assembly efficiency using current-day design processes to produce a standardized configuration; thus, improving interchangeability, maintainability, and to the maximum extent possible, lowering lifecycle cost.
Impact on Warfighter:
- Increase robustness of the supply chain
- Decrease lifecycle costs
- Improve warfighter readiness
- Reduce maintenance and repair times
DOD Participation:
- Air Force T38 SPO Personnel
Industry Participation:
- Wichita State University (WSU) – National Institute for Aviation Research (NIAR)
- NCMS
Benefit Area(s):
- Cost savings
- Repair turnaround time
- Obsolescence
- Mx management improvement
Mx Focus Area:
- Reliability Improvement (Hardware)
