System 3R cuts BAe set-ups from hours to minutes

Citation

(1999), "System 3R cuts BAe set-ups from hours to minutes", Aircraft Engineering and Aerospace Technology, Vol. 71 No. 2. https://doi.org/10.1108/aeat.1999.12771bab.012

System 3R cuts BAe set-ups from hours to minutes

System 3R cuts BAe set-ups from hours to minutes

Keywords Palletising, System, 3R

System 3R's ZeroFix, the pallet referencing system, is reported to be reducing set-up times from hours to minutes on what is claimed to be the world's largest machine tool palletisation facility installed at the Chadderton factory of British Aerospace Military Aircraft & Aerostructures (Plate 3). It has helped BAe to win major orders from aircraft manufacturers around the world, and thus secure jobs at the factory for the future.

One of their ongoing contracts is making wing components for Rockwell, the North American aerospace specialist, who build the new Boeing 737s as well as other aircraft types.

Plate 3 The gantry crane places a "loaded" pallet onto the 13ft wide machine bed

Ten huge pallets, each 6m × 4m and weighing eight tonnes, are used in the process ­ two on the machine tool and eight off, in the pre-production loading bay. ZeroFix provides speedy, fool-proof off-line setting-up using System 3R's 3Retix X, Y and Z reference system which ensures accuracy to within a few microns. Machining continues uninterrupted, because pallets can be removed and replaced with complete confidence, knowing that references are all in exactly the same place.

Traditional set-up methods would have taken BAe engineers several hours but, as System 3R's ZeroFix works on only one primary and one secondary fixing point, times are said to be significantly cut to minutes. It also maximizes efficiency and eliminates interruptions (Plate 4).

BAe's initial investment in this new palletisation process, which is based on an existing Cincinnati Milacron CNC machine with a 65ft long working bed, is the culmination of a special project team's intensive research. In fact, the production concept has subsequently won a prestigious British Aerospace Silver Award for its highly innovative solution, based on the principle that the machine never stops.

Plate 4 System 3R's ZeroFix uses a straightforward three point reference system which ensures accurate repeatability and fast set-up times

Malcolm Woodhead, BAe's Engineering Manager, said, "When we looked closely at Chadderton's production output potential, we knew that we had to make significant changes in order to remain a leading player in this highly competitive arena, and continue winning substantial orders, such as the Boeing contract. Our research took six months of intensive but interesting pathfinding work before we arrived at the new palletisation system.

"From a design point of view, the Boeing parts are quite sophisticated but palletising the materials for machining on this scale has proved successful and continues to work reasonably well", according to Malcolm Woodhead. "Palletisation allows us to maximize the capacity of both machines."

The Chadderton machine bed is 13ft wide with three vertical machining heads across its width. The pallets are placed on the bed two at a time, using a massive gantry crane which straddles the entire operation. Eight pallets are always in the pre-production bay being loaded with the raw material, a mix of aluminum billet and T-cord extrusion, depending on the wing part being machined.

The advantages of System 3R's sophisticated ZeroFix set-up procedures have now been replicated on a second machine at Chadderton in order to meet increased production demands as a result of BAe securing similar contracts.

Details available from System 3R (UK) Ltd. Tel: +44 (0) 1844 274455; Fax: +44 (0) 1844 342296; E-mail: info@systems-3r.co.uk