Multi-Floor Aircraft Sub-Assembly Layout for Space-Constrained Production
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Solution Overview
Problem
The existing aircraft sub-assembly manufacturing systems require large amounts of floor space due to the size and weight of components and jigs, limiting production efficiency in facilities with space constraints.
Innovation Solution
A multi-level manufacturing system is implemented, where components are assembled on a mobile jig on a first floor and then moved to a second floor for further processing, reducing the footprint by relocating non-jig-dependent workstations to the second floor, utilizing elevators to transport the sub-assembly between floors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mass production line with sequential workstations is used on the floor, then manufacturing functions can be fulfilled, but a large amount of floor space is required
Solution Approach 1:
The patent applies vertical dimensionality by implementing a multi-level manufacturing system where workstations are distributed across different floors. The first floor houses workstations requiring the jig (component assembly, jig attachment), while the second floor houses workstations that do not require the jig (component fitting, painting, curing). This vertical arrangement reduces the horizontal footprint while maintaining all necessary manufacturing functions.
2Productivity
If workstations are arranged sequentially on one floor, then production flow is maintained, but space efficiency is reduced
Solution Approach 1:
The production flow is maintained by introducing vertical movement between floors. The jig travels horizontally on the first floor for assembly operations, then is vertically transported to the second floor for subsequent operations. This three-dimensional production path preserves workflow continuity while compressing the horizontal space requirement.
Solution Approach 2:
The manufacturing system is segmented into two distinct floors with specialized functions. The first floor is dedicated to jig-dependent operations (component assembly, jig attachment), while the second floor handles jig-independent operations (component fitting, painting, curing). This segmentation allows optimized space utilization on each floor while maintaining overall production efficiency.
3Adaptability or versatility
If the jig remains on the facility floor throughout manufacturing, then all workstations can access the sub-assembly, but the facility footprint increases
Solution Approach 1:
The jig is strategically relocated to the second floor after completing its function on the first floor. This vertical relocation allows the first floor space to be freed up or repurposed, while the second floor provides dedicated space for workstations that require direct jig access. This dimensional transition optimizes both space utilization and workstation accessibility.
Data Source
AI summary
An aircraft sub-assembly manufacturing system is arranged over multiple floors of a manufacturing facility. A production line of workstations 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 is arranged to transport the assembled aircraft sub-assembly between the first floor and the second floor of the facility.