An Integrated Lean Approach to Aerospace Assembly Jig and Work Cell Design Using Digital Manufacturing.

Abstract

This paper examines the use of integrated digital manufacturing methods for the design of an aircraft panel assembly jig and its associated work cell. The existing jig design and assembly sequence for the Bombardier CRJ700/900 regional jet apron and uplock panel assembly was reviewed. A digital simulation of the new CRJ1000 apron and uplock assembly incorporating a conceptual design for a new jig, was produced. When the jig format was finalised its simulated performance was compared to that of the CRJ700/900 to identify any process improvements in terms of tooling cost and panel build time. It was predicted that the digitally assisted changes had brought about a 4.9% reduction in jig cost and a 5.2% reduction in panel assembly time. It was concluded that the reduction in assembly time was due to improved jig functions and ergonomics as well the implementation of lean principles to the work cell design. The cost was reduced by applying design for manufacturing and assembly (DFMA) principles through the digital medium as well as the reduction in design iterations required because of the use of digital manufacturing.