Since the early 80’s aircraft engine providers have used complex assemblies of 3D computer-aided design (CAD) data to assist in the engi­neering design of components. This process eliminated the need to create expensive physical mockups used for interference and clearance checking. But even with complete 3D defini­tions, the downstream assembly/disassembly planning process, and associative documentation, is still developed using an Engineering Bill of Material (BOM), 2D drawings, and specifica­tions. Assembly/disassembly planning and documentation remains a manual process that is often dependent on the skill and experience of the individual defining the process.

This project utilized commercial software solutions from Siemens PLM Software integrated with technology developed by General Electric (GE) Global Research.  The Siemens solution provides the needed infrastructure (multi-tiered environment which includes data architecture, graphics engine, and simulation environment) and the GE technology provides the necessary algorithms to automatically create and edit an intelligent assembly and disassembly sequence based on complex geometric shapes. The resulting technology solution is unique in industry.

Initial trial of the system achieved reductions in assembly process planning cycle times from about 30 days without the automation developed in this project to 15 days with it – a 50% reduction. Assuming a fully loaded labor cost of $50/hour, that is a savings of $6,400 per assembly. Benefits will accrue to downstream functions, depots and to operations support in terms of reduced errors, reduced maintenance cycle times, and reduction in training requirements. Direct cost avoidance savings will be realized in Engineering Change cycles for assemblies. Achieving benefits will be dependent on the availability of electronic delivery of 3D animated work instructions. New platforms such as the Joint Strike Fighter (JSF) may see immediate maintenance benefits. Since depots use work instructions developed by OEMs, depot benefits will be achieved through change management efficiencies and through the use of templates for work control planning.

CTMA projects Product Lifecycle Management (PLM) for Six-Sigma Quality and AD&D conducted at GE resulted in very significant cost savings from prevention of quality “escapes” and from productivity gains throughout the design-to-manufacturing value stream. Deployment of PLM for Six-Sigma and AD&D tools is estimated to save approximately $13 to $15 million with a resulting payback period on investment of approximately six months. This savings is based on an activity level associated with executing approximately 800 new part launches and 1,200 design changes per year.

DoD Participants include the U.S. Air Force – Oklahoma City Air Logistics Center (OC-ALC)
and U.S. Marine Corps – Albany MC3.


The NCMS contact is Tony Haynes, tonyh@ncms.org, 734-995-4930.

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