Boeing's measurement system reduces jet fighter's cost

Highly sophisticated electronic measurement tools that helped Boeing reduce tooling costs for its Joint Strike Fighter (JSF) X-32 concept demonstrators by 72% over the F-22 will be used to achieve even greater cost reductions in the next phase of the JSF program, according to the aerospace giant.

Using conventional measurement tools, shop personnel measure parts electronically with special readers after the parts are built and assembled. The data gathered by these systems are then translated and cross-checked against engineering specifications.

The new way involves integrating 3D solid modeling and design software with this measurement software, allowing shop personnel to verify part quality and fit much earlier in the assembly process, substantially reducing factory flow time over comparable aircraft programs.

"We are not relying on demonstrations to validate these processes. We have already used them on the X-32 and used earlier versions successfully on the F/A-18E/F and the F-22. We're expanding their use on the JSF," says Jim O'Neill, chief engineer for JSF Structures and Systems.

Boeing expects to reap hundreds of millions of dollars in savings in JSF development and production costs by using innovative measurement systems that reduce tooling and cycle time.

"Designing, building and maintaining tooling can account for as much as 40% of the total start-up costs of a conventional aircraft production program," says Terrance Massie, manager of Tool Engineering and Sustaining. "Even a tooling reduction of a few percent can add up to millions of dollars in savings."

Boeing recently demonstrated the power of integrated measurement systems for its US/UK government customer when it built a full-scale JSF stealth-validation aircraft model using no tooling except for simple holding stands. By eliminating the need for skin-placement tools, the company avoided more than 600 hours of tool design and fabrication time.

Boeing also is integrating several different computer-aided measurement systems in a common user interface. This reduces training time by approximately two-thirds and helps operators gain proficiency in multiple systems.

"Our goal has always been to build quality into the process," Mr Massie says. "These improvements are helping us reach that goal and save money."

Wireless communication will give measurement-system operators immediate access to drawings, status reports, web pages, e-mail and all other traditional desktop features upon demand at the worksite. This information will be stored as part of the advanced configuration management system Boeing established for the JSF. Wide access to this common database will enable a "design, build, support anywhere" philosophy.

One-stop shopping plan for machine tool needs

You can't catch a movie at the multiplex or sample goodies in the food court. But, beginning next year, you will be able to meet your machine tool and manufacturing needs--all under one roof--at the Machine Tool Mall.

Machine Tool Mall

The owners of Maintenance Service Corp are developing the mall in New Berlin, WI. It will have 90,000 sq ft available for national or regional offices, warehousing, showrooms, and manufacturing facilities.

A variety of shared services will be available including mechanical and electrical engineering support, truck loading/unloading, way grinding, laser calibration, and payroll.

Clausing will sponsor Dodge Winston Cup team

Clausing Industrial Inc will sponsor the Dodge Motorsports NASCAR Winston Cup Program racing team, owned and managed by Ray Evernham.

Beginning with the 2001 Daytona 500, Clausing's sponsorship will include providing machine tools used by the Dodge Winston Cup team. The race cars--four Dodge Intrepid R/Ts, are being built at Mr Evernham's 40,000-sq-ft facility in Charlotte, NC, in cooperation with Dodge engineering and design groups.

"Being part of a racing team is about more than winning," says Bill Nancarrow, president of Kalamazoo, MI-based Clausing. "It's an opportunity to demonstrate the quality of the products we offer. If they make the grade on the race track, our customers can be certain their machine tools will deliver the same high precision on the shopfloor."

NAE honors century's engineering achievements

Speaking on behalf of the National Academy of Engineering (NAE), astronaut/engineer Neil Armstrong recently announced the Greatest Engineering Achievements of the 20^th Century.

"Almost every part of our lives underwent profound changes during the past 100 years thanks to the efforts of engineers, changes impossible to imagine a century ago," Mr Armstrong said, adding, "as someone who has experienced firsthand one of engineering's most incredible advancements--space exploration--I have no doubt that the next 100 years will be even more amazing."

Initiated by NAE, the project celebrated technological accomplishments of the past 100 years. Other key partners in the project were National Engineers Week and the American Association of Engineering Societies. Primary sponsor was the United Engineering Foundation. The achievements--nominated by 29 professional engineering societies--were selected and ranked from a list of 105 selections by a committee of academy members. Advancements were rated by weighing the greatest contribution to the quality of life during the past 100 years.

Here is the complete list of achievements:

The NAE notes that the top achievement, electrification, powers almost every pursuit and enterprise in modern society. It has literally lighted the world and impacted countless areas of daily life, including food production and processing, air conditioning and heating, refrigeration, entertainment, transportation, communication, health care, and computers.

Based in Washington, DC, the NAE is an autonomous nonprofit organization of engineers.

TRW to build new plant in Poland this summer

TRW Chassis Systems will construct a new $7 million, 7000 sq meter manufacturing facility for braking actuation units in Gilwice, Poland. TRW has signed a land purchase deed and expects to begin construction this summer.

Currently, the Livonia, MI-based TRW division has three plants in Poland: one in Czestochowa that manufactures seat belts and airbags, one in Czechowice-Dziedzice that produces steering gears, and a third plant in Warsaw that makes automotive electronics components.

Construction is expected to be complete by February 2001, with production slated to start in October 2001. At full production, the new facility is expected to employ about 350 workers.

Boeing and Mitsubishi enhance business ties

The Boeing Co and Mitsubishi Heavy Industries Ltd (MHI) have signed a memorandum of understanding to expand their broad cooperative relationship covering aerospace and other business areas.

"Boeing and MHI have been working closely together for more than 30 years, and this agreement extends that long and mutually beneficial relationship," the Seattle-based aerospace giant said.

In recent months, Boeing and MHI have cooperated in developing programs for space businesses, such as the announcement of a joint effort to design and develop a new upper-stage propulsion system, designated the MB-XX. Additionally, Boeing and MHI continue feasibility studies of mutually beneficial projects involving commercial jetliners, electronic systems, launch vehicles, and manned and unmanned space systems.

Brown & Sharpe DEA in Ford's Amazon project

Brown & Sharpe DEA has been selected by Ford Brazil as technological partner for their Amazon project.

Amazon involves building a new manufacturing facility in Camacari-Bahia, Brazil to produce the Ford B platform (Fiesta). The facility is scheduled to be operational by August 2001.

As part of the project, Ford will invest more than $7 million in a major distributed shopfloor inspection system to check the dimensions of sheet metal components, such as body panels, body-in-white assemblies, and sub-assemblies. The installation includes five horizontal arm Brown & Sharpe DEA Vento direct computer control (DCC) coordinate measuring machines configured in a rugged version for shopfloor applications.

Two of these CMMs--a 6-meter-long (X-axis) single arm machine to be installed in the stamping plant, and a dual-arm machine of the same length in the welding department--will be used to inspect a variety of sheet metal panel sizes and shapes.

The other Brown & Sharpe DEA CMMs will be integrated into a robotized welding line developed by Comau, another major Ford partner, for process control measurements.

A sixth machine, a dual-arm 12- meter (X-axis) Vento, will be installed in an air-conditioned room for the dimensional verification of precision tooling.

Stanley Machining is new partner with ABB

Stanley Machining Inc, Toledo, OH, has signed a contract as an ABB Systems integration partner for the Robotic Products Div of the Manufacturing Industry and Robotics Group of ABB Flexible Automation. With this alliance, SMI adds articulated arm robots to its systems and product offerings.

ABB Flexible Automation is a leading supplier of robot products for flexible automation systems used in a wide range of industrial and automotive applications. SMI specializes in the design and build of custom systems to bring improvement, efficiency, quality, and cost effectiveness to the manufacturing process. SMI supplies automated systems for assembly, welding, inspection and materials handling. SMI has complete capabilities for design, manufacture, runoff, and installation of production ready systems. The company also specializes in tooling and fixtures for these automated processes. SMI installs and supports equipment throughout North America.

The company's installed systems include arc and laser welding lines, tube forming and assembly lines, glass transfer and processing systems, multi-component assembly systems, vision inspection cells, press loaders/ unloaders, laser marking, laser trim, machine tending, and custom machining cells.

MachineTools.com launches financing center

MachineTools.com, a leading B2B e-commerce site for the machine tool industry, has launched its Financing Center, offering endusers with access to an "instant credit" process for machine purchases and other business needs.

The MachineTools.com Financing Center will require no application fees for loans under $750,000, and will provide credit approvals for up to $5 million, the Chicago-based company announced.

The Financing Center will facilitate automated financing for qualified applicants up to $100,000 for both on-line and off-line business transactions.

Originally published in the July 2000 issue
of Tooling & Production.
Please Note: some pictures or diagrams are only available through the printed media.