Reduction of Part Counts and Composite Materials for Aircraft Structures

Based on the 3 types of quality costs that have been discussed and reviewed above, I recommend that we look at doing more appraisals and inspections during the manufacturing process, this will limit the number of design changes that happen early in the process but it should help in cutting down our external failure costs and help limit

First of all, the material cost element could be affected by the part weight driver under Design, material cost driver under Geography and scrap and defect driver under both Design and Operations. According to the data collected, Design will not cause any cost difference because each injection molded part is made with the exact same specifications in all regions. As a result, the material cost driver is the most important cost driver for the

The customer, internal departments, and potential suppliers contribute to designing quality into molded parts. Due to Road-Master’s strict quality requirements and just-in-time inventory systems, nonconformance results in high costs, hinders customer relations, and endangers

However, the absence of plastic deformation does not mean that composites are brittle materials like monolithic ceramics. The heterogeneous nature of composites result in complex failure mechanisms which impart toughness. Fiber-reinforced materials have been found to produce durable, reliable structural components in countless applications. The unique characteristic of composite materials, especially anisotropy, require the use of special design

I would like to relate “Does America Really Need Manufacturing” article with Harvard Business School Case study of Boeing 787 Dreamliner. According to the article, Boeing came up with new manufacturing idea for their 787 Dreamliner project; before Boeing used to follow “Built to Print” manufacturing process in which they will design and draw each and every part of the plane and then offer contract to build those parts with precise specification. But, for this project they changed their manufacturing process to “Built to Performance” in which total responsibility, starting from design to finish part was given to their partners (suppliers) all over the world. By doing so, they saw a significant decrease in their cost, but on the other hand they

Analysts predict that the Aerospace and Defense industry will experience a number of trends over the next few years. First, the changes in global economy in the Asia/Pacific regions will shift the largest market from North America and Europe to the Asia/Pacific market (Hoover’s, 2018). Second, manufacturers will implement more sustainable and affordable operations. For example, manufactures are researching materials science to develop composites. With composite materials

Fraser Company has been the supplier of metal and plastic fabricated parts for Boeing Aircraft and has recently celebrated its 50th anniversary. In the 1960s, in order

To be successful many large scale manufacturing operations must find a keen balance that addresses the more task-focused needs of the production process as well as the financial planning, oversight and control requirements of any major modern business organization. As I have mentioned couple of points in the above section, but here in this critique I will be talking about how sourcing can help a company to make a decision regarding keeping its manufacturing unit in United states. Modularity plays an important role in sourcing as we can see from the article, where modularity in product design can be seen as a way to new product development. Modularity in process design may speed new product manufacturing setup times, reduce costs, and enhance the profitability of the lower product volumes. Modular products tend to have fewer components for assembly and are therefore cheaper to assemble. Modules are created with some aspects of production in mind, however this modularization is done without understanding the implications of design. Although often yielding highly functional products, once the manufacturing process is over this unstructured modularization often leads to costly redesigns or expensive products. Modularity requires maintaining independence between components and processes in different modules, encouraging

To reduce cost and maximize efficiency a single line production and a common production line will work in concert with a simple design method to reduce the aeronautical components by 40 percent in turn requiring 75 percent less support equipment for maintenance. The F-35 is projected to reduce the life cycle cost by over 50 percent saving the Department of Defense an estimated $32 million per aircraft compared to the F-22. The F-35 is the currently has the most advanced strike technology incorporated into affordable package as the future and will support our nation for the next 30 plus

There is a multitude of aerospace manufactures in the business of building airplanes worldwide such as Boeing and Lockheed Martin. In order to become a global leader in an ultra-competitive market, such as the aerospace industry, Boeing implements cost reducing initiatives such as lean manufacturing practices. In order to build a complex item such as an airplane on time and on budget, a manufacture will require a competent supply chain management system to ensure all the needed parts are available to the builders. Implementing technology such as automated equipment to assist in the reduction of human errors and fatigue will reduce costs associated with rework caused by human error mistakes.

If Aircraft Solutions is your choice of flight, they promise and stand by the development and implementation of product support strategies to ensure supportability is considered throughout the system life cycle. Aircraft Solutions is able to provide you with conciliation by coordinating with different types of business units to support production and the development of products whether they be new or existing, maintain documents for all support activities, provide product trainings to staff members, guide teams in working with problems our customers may have, and actually fix the problem. Aircraft Solutions have partnered up with Boeing engineers to create a spreadsheet that shows the performance analysis of new products and enhancements,

De Havilland is a Canadian aviation company that is in the process of determining how to contract out the supply of its flap shrouds and equipment bay doors for its Dash 8 aircraft. Its current supplier, Dollard Plastics is believed to be charging a large premium over market price and for that reason, a completive tender was issued to test De Havilland’s hypothesis. After receiving bids from 9 companies, a strategic review of De Havilland’s options and alternatives was conducted. Based on this review, it is recommend De Havilland ceases its contractual relationship with Dollard and instead enters into a contract with Marton Enterprises. Although entering into a contract with Marton puts forth the issue of whether or

Boeing’s newest jet, the 787, is made out of composite plastics and carbon fiber in order to

We would recommend that BMW use the actual parts instead of substitute parts; for example, using sheet metal instead of fiberglass when developing new series models. This will help BMW detect problems earlier in the production process and make quality improvement a much easier task to achieve. Since they are using suppliers that will manufacture parts using specialized tooling, BMW should also reduce the amount of prototype batches from five to three. The first prototype batch should be done using its current process of hand design, the second prototype will use pre-production process and the third will incorporate the use of specialized tools. Using this process will significantly decrease prototyping cost and lead time.

I am in pursuit of a life where the education I choose lets me explore the wealth of knowledge and wisdom. I strongly recognize that manufacturing engineering is the domain where my purpose and passion mingle. It is my earnest belief that the education in manufacturing engineering that I have received until now has helped me to grasp the fundamental principles of the subject. This knowledge, when coupled with dedicated master’s study would be the ideal preparation for a career in applied research or academics in the manufacturing industry, a vast field of science from developing new materials to manufacture an aircraft. After giving a visit to an Aero India Show last year in Bangalore has, developed a curiosity in me to know the manufacturing world of an aerospace industry. It is for this reason that I wish to pursue a Masters course in Aerospace Engineering in the “Aerospace Structures and Materials track” from Delft University of Technology.