Vertical Aircraft Sub-Assembly Flow for Space-Constrained Production
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Solution Overview
Problem
Aircraft sub-assembly manufacturing requires extensive floor space due to the size and weight of components, jigs, and multiple workstations, limiting production efficiency in facilities with space constraints.
Innovation Solution
Implementing a multi-level manufacturing system where components are assembled on a mobile jig on the first floor and then moved to a second or third floor for further processing, allowing workstations without jigs to be located above, reducing floor space requirements and optimizing jig usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If all workstations are located on the first floor with the mobile jig, then all manufacturing steps can be performed on a single level, but the facility requires extensive floor space and has high load-bearing requirements
Solution Approach 1:
The production line transitions from a single-floor horizontal layout to a multi-level vertical configuration. Workstations that do not require the mobile jig are relocated to the second floor, utilizing the vertical dimension to reduce the horizontal footprint of the facility while maintaining production flow.
2Productivity
If workstations are distributed across multiple floors, then floor space is reduced, but vertical transport of components and jigs is required
Solution Approach 1:
Workstations are segmented into two groups based on their requirements: those needing the mobile jig remain on the first floor, while those not requiring the jig are placed on the second floor. This segmentation enables vertical separation of functions and optimizes space utilization.
Solution Approach 2:
The mobile jig acts as an intermediary that remains on the first floor while components are vertically transported to the second floor for processing at workstations that do not require the jig. This intermediary approach facilitates multi-level operation without requiring the jig to be moved vertically.
3Weight of stationary object
If the mobile jig remains on the first floor while components are moved to the second floor, then load-bearing requirements of the second floor can be reduced, but selective workstation placement is required
Solution Approach 1:
Different floor locations are assigned different functions based on their load-bearing characteristics. The first floor, with higher load capacity, houses the mobile jig and heavy component assembly areas. The second floor, with lower load requirements, accommodates workstations that process lighter assembled components.
Data Source
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AI summary
An aircraft sub-assembly manufacturing system is arranged over multiple floors of a manufacturing facility. A production line of workstations (270, 330, 335, 340) is provided at locations at both a first floor and a second floor of the facility, each of the workstations being arranged for providing manufacturing steps for the aircraft sub-assembly. Elevator apparatus (215, 220) is arranged to transport the assembled aircraft sub-assembly between the first floor and the second floor of the facility.