Most Agile & Expensive($350B) LM Fighter Transform Manufacturing Process
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Transcript of Most Agile & Expensive($350B) LM Fighter Transform Manufacturing Process
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
The F-35 Lightning II – Focused on Affordability
Dr. Don A. Kinard
LM Senior Fellow
Deputy, F-35 Fighter Production System
NC Aerospace Suppliers Conference
August 2012
© 2012 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
STOVL Carrier Trials
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
F-35A F-35B F-35C
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Economies of Commonality and Scale
Key Tenets Counters Current and Future Threats
An Effective Coalition Lower Life-Cycle Costs
Global Security Industrial Cooperation
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
F-35 Design/Supply Chain Roles
Integrated Airframe and Systems Designs
NGC
Center Fuselage
Systems Responsibilities
Weapons Bay Door and Drives
Arresting Gear
Radar
IFO Doors (Fokker)
BAES
Aft Fuselage
Vertical Tails
Horizontal Tails
CV Wing Fold
Systems Responsibilities
Fuel System
Crew Escape
Life Support
EW System
Throttle/Side Stick
Flight Control Computer
LM FW and LM Palmdale
Overall Air Vehicle
Edges
Wing
Fwd Fuselage
Mate thru Delivery and Finishes
Systems Responsibilities
Autonomic Logistics
Mission Systems
Vehicle Systems
Training Systems
Team Harnesses (Fokker)
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
F-35 Major International Production Plan
BAES
Vertical Tails
• Australia
Horizontal Tails
• Denmark
• Canada
CV Wing Fold
• Canada
NGC
Center Fuselage
• Turkey
LM FW and LM Palmdale
Conventional Edges
• Denmark
• Norway
• Netherlands
Wing
• Italy
Final Assembly and Check-out
• Italy
Strategic Second Sourcing for Major Subassemblies
Capacity and Business Case Driven
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Contracts Overview
Current Aircraft Production
Aircraft in Ground Test
and Flight Ops
SDD (18 A/C)
LRIP 1 (2 A/C)
LRIP 2 (12 A/C)
LRIP 1 (2 A/C)
LRIP 2 (12 A/C)
LRIP 3 (17 A/C)
SDD (19 A/C)
In FW Assembly
LRIP 4 (32 A/C)
Rolled Out
LRIP 3 (11 A/C)
BF-5 at Pax
AF-9 at Eglin
Delivered to Test site or Base
LRIP 5 (30 A/C)
On Order
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Transforming Manufacturing Processes
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© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
X-Plane “Craft” Production F-16 “Mass” Production F-22 Lean Production System
F-35 Fighter Production System
F-35 Fighter Production System Evolution
BAE Systems Northrop Grumman Lockheed Martin
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Global Suppliers People (Performance)
Designing a Lean and Integrated F-35 Production System
Tooling and Facilities
Product Design
Processes and Systems
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Digital Thread Throughout Life-Cycle
Design
Development
Support,
Maintain
and
Train
Build
Test
Program
Management
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
STOVL 7085 Aluminum FS 496 Bulkhead
Forging and Finished Part
Weight/Cost Trades Drove Material/Structural Selections
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
F-35 Fort Worth Factory Transition
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Macro Material Flow Capability and Vision
FMF / SC&D Overview and Benefits
Engineering Supply Chain
Network
Inbound
LogisticsSource of Repair
Information
Financial
Material Warehousing Production Sustainment
Factory Flow SC&D
Supplier Collaboration & Development Assembly Operations
Demonstrated consumption-based
replenishment system with harnesses
in the J240 work cell
Implemented part-presentation and
harness sub-assembly improvements
for use on manufacturing line
Re-sequenced crew plan to improve
work flow and reduce span time
Improved integration with planning
process to enhance management
visibility into production status
The FMF and SC&D teams are architecting the entire supply chain to support production requirements
by better integrating suppliers, logistics, warehousing and production to meet 1/day rates
Warehouse Flow Center
Reduced number of touches to pick
and kit parts
Minimized idle time between process
steps, excessive motion, and
unnecessary transportation
N
Receiving Shipping
Oth
er
Gov’t
Wing Staging F
F
Sta
gin
g
M&F Staging
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
New Automation Technologies at NGC
• Inlet Robotic Duct Drilling (IDRD)
– Robotic System Guided by
Laser Metrology System
• Automated Guided Vehicles (AGV)
– Automated Transportation of
Components from Station to
Station.
• Automated Drilling Systems (ADS)
– Highly Accurate Gantry Component
Drilling System (including
Interchangeable Hole Patterns)
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
430 Assembly Extension 1 430 Empennage Pulse Line Layout
430 Aft Fuselage Pulse line Pulse Line System
BAE Flow Based Assembly Pulse Line Concept
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Robotic Coating Process
Higher Quality, Reduced Span, Lower Cost
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Automated Drilling
Laser Ultrasonic Inspection GraphicalWork Instructions
Fiber Placement
Advanced Manufacturing Technologies
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Laser Projection of Materials and Decals
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Work Instruction Optical Projection
Using the Digital Thread
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F-35 Learning Curve
300,000
250,000
200,000
150,000
100,000
50,000
0
Labor
Hours
SDD LRIP 2 L1 LRIP 3
Assembly Direct Touch Labor
CV
CTOL
STOVL
F-35 STOVL 61%
F-35 CTOL 69%
LM Legacy 69%
Learning Curve
World-Class Learning Curve Producing 3 Variants on a Common Line
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Future Affordability
So What Are We Doing About it?
• Additive Manufacturing of Titanium
• Laser & Cryo Machining Projects
• Automation (Lasers, Robotics)
• Lower Cost Precision Machining
• Application of Lessons Learned
– SDD to Production
– Phase 3 EMAS
– Final Assembly Improvements
• SCM Initiatives
– Multi-Year Packaging
– Best Value Sourcing
– Technology Insertion
© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Summary
• Transitioning the Fort Worth Final Assembly
Factory
– From F-16 State of the Art to F-35 State of the Future
• Build and Transition a Global Supply Chain
– Exploit the Digital Thread
– Attack the Cost Drivers
– Design for Precision Manufacturing
– Implement Automation and Motion Based Processes
– Enforce the Best Value Economic Model
– Share Supply Chain Risk
• Capture Economies of Commonality and Scale