CASE STUDY 1
The Client
A leading global aerospace prime with
a strong presence in both commercial and military markets.
The Component
The component was part of an engine actuation system for
a single engined plane and, being a single line component, was flight
critical. The manufacturing
process was complex, requiring high tolerances and surface finishes to
be achieved after a casting.
The Challenge
Casting supply was unreliable because it the part was
tricky to cast and only small quantities were required. The part suffered
from porosity
and distortion both before and after heat treatment.
Lead-times were long,
yield was poor and the finished product was extremely expensive.
The solution
Graves saw benefits from developing
the component from readily available bar stock which would eliminate
all the delivery problems associated
with casting at a stroke.
The process route was redesigned including route
planning, tooling design, cnc programme construction, process control
and a quality plan.
The first batch of components were manufactured successfully
and released with a first article inspection report.
The Result
• Dramatically reduced lead time, including planning time!
• Improved process stability
• Reduced variability in the manufacturing process, uniformity and finish
• Reduction in number of suppliers in the chain
• Removed yield loss due to casting porosity
• Superior product within required lead time
• Costs saving across the supply chain
|
CASE STUDY 2
The Client
A leading global aerospace equipment manufacturer supplying jet engine
control systems.
The Component
This highly complex part had traditionally been manufactured by the
customer because of the difficult manufacturing process and importance
of low variability.
The in-house process required the manufacture
of a high precision sleeve and end fitment.
The sleeve was manufactured
from a malleable nickel alloy billet which was machined to a very thin
and fragile structure. Tolerances for flatness
and squareness were tight!
The end fitment was manufactured from a solid
billet, machined to a thin walled structure then nitride hardened in
specific areas.
The two components were aligned and beam welded to form
the whole assembly which was then completed by a turning process.
The Challenge
Yield was poor due distortion caused by the
beam welding process.
Graves took on the manufacture of this assembly with the aim of reducing
losses through tighter controls during manufacture.
The Solution
The root cause of the problems was maintaining tolerances during
the beam welding process. Calculations were made for fusion weld shrinkage
and distortion accounted for. Tooling was designed and manufactured to
keep the components accurately aligned during welding.
Tight tolerance processes were moved to post welding to ensure the tolerances
and surface finishes could be maintained.
The Result
• The
first 100% yield batch of this component - ever!
• Product variability reduced and process capability increased dramatically
• Overall acquisition costs substantially reduced.
|