Big Button Model
Based Assembly
Jim Lind
Boeing IDS
Scott Sandwith
New River Kinematics
CMSC 2003 July 21-25 2003
Introduction: Model Based Assembly
• Integrate engineering design,
Measurement Plan Script with
advanced metrology in an easy to
use interface
• Improve cost and quality by
simplifying aerospace
manufacturing
• Simplify assembly and build
processes by implementing and
quickly delivering integrated
production-ready solutions
• Minimal operator learning curve
Motivation: Produce Product
• Move away from large
assembly tooling
– Less complex / lower cost
– Mobility / smaller footprint
• Engineering tolerances
remain critical
• Increasing production
rates
• Limited skill base
• Technology learning
curve
Automation ROI
• Existing Tool Routine
– Subset average 34 hours
– 110 hour average
• Automating Tool routine
– Subset demonstrated in 3
minutes
– Overall projected within 1
shift
• Time savings not enough
– Multiplier for reduction in
Production Disruption
Embedding Metrology Solutions
• Transparent to mechanic
– Process not technology training
– If done well, they may not
realize they are operating
precision metrology equipment
• Simple interface
– Work instructions displayed
with big action buttons
– Results displayed with big action
buttons
• Automatic reporting
Benefits
• Single person operation
possible
• Speeds up process
• Improved repeatability
• Quality check built into
process
• Consistent, traceable
results
Benefits
• Optimize product performance
• Cost savings and flow time reduction
– Maintenance and time
– Set/Inspect part features directly from CAD
– Reduces measurement tolerance guess work
• Part specific template and general
measurement plan support custom
configurations directly on the shop
floor without reprogramming
• Relationship between features are
optimized directly!  Build / Inspect
• Integrate assembly configuration for
design/tolerance improvements
• CAMS Reaches High-Tech Milestone In Support of
F/A-22 Aft Fuselage
• The Computer Aided Measurement Systems (CAMS) organization
recently demonstrated a new process improvement using a scripting
program, which measures F/A-22 aft fuselage parts to ensure proper
fit. The old process involved hand-guided measuring, which took up
to six hours and time-consuming set-up. After months of research
and testing, the CAMS organization is now able to program specific
coordinates into a database that tells the laser tracker and computer
exactly what, where and how to measure. Automating this process
reduces the flow time by 87.5 percent from the old process and could
yield approximately eight hours of processing time on future builds.
“While this represents a very significant savings, we expect savings
as great, or greater as we integrate Model Based Assembly – using
the CATIA model as the authority to do the aircraft assembly – into
our manufacturing processes,” said Ed Baker, Emergent
Manufacturing & Tooling senior manager.
CAMS Reaches High-Tech Milestone In Support of F/A-22 Aft Fuselage
“…reduces the flow time by
87.5 percent…”
CAMS Reaches High-Tech Milestone In Support of F/A-22 Aft Fuselage
“…we expect savings as
great, or greater as we
integrate Model Based
Assembly into our
manufacturing processes.”
Ed Baker, EM&T senior manager.
Simulation of Application
Direct Project Benefits (Overall)
• OLD
– 142,000 lbs. steel
– $14 million fabrication
– ~ 3150 sq. ft. footprint
– Future – rate tools?
• NEW
– < 1 ton
– < $ 1 million to fabricate
– Assemble 3 or 4 sections
in the same footprint
– Flexibility – move assets
to support need
Summary
• Big Button Model Based Assembly improves
over traditional processes
• Reduce the amount of tolerance information by
working directly with the critical features
• Preparation, Setup, and Flow time are
minimized
• Direct use of the CAD Geometry improves part
and trend analysis
• Using part tolerances instead of tooling
tolerances enables significant cost savings
Acknowledgements
• Ed Baker, John Costello and Barry Cooke
of Boeing
• Dr. Robert Salerno, Dr. Joseph Calkins,
Bruce Thomas, and Rick Cole of NRK