Lockheed Martin uses eM-Tolmate at heart of new system to optimise industrial processes

Citation

(2001), "Lockheed Martin uses eM-Tolmate at heart of new system to optimise industrial processes", Aircraft Engineering and Aerospace Technology, Vol. 73 No. 3. https://doi.org/10.1108/aeat.2001.12773cab.013

Lockheed Martin uses eM-Tolmate at heart of new system to optimise industrial processes

Lockheed Martin uses eM-Tolmate at heart of new system to optimise industrial processes

Keywords: Lockheed Martin, Tecnomatix, Software

The joint strike fighter (JSF) (Plate 3) team at Lockheed Martin, the US aircraft designer/developer, is reported to be using eM-Tolmate, from Tecnomatix Technologies, to help produce significant savings through reductions in engineering changes, tooling, and scrap and rework.

Plate 3 Artist's impression of the joint strike fighter aircraft, currently under development

The Tecnomatix software is now fully implemented at Lockheed Martin Aeronautics Company, which is leading the corporation's efforts on the JSF programme, forming the cornerstone of a process called variation management (VM). It is used to define, predict, measure and analyse tolerances throughout the industrial process. Since implementation, it has ensured that tolerances are accurately specified during product design and fully adhered to during manufacturing and assembly processes.

VM is said to reduce assembly variation during the design and manufacture of products. The initial phase involves a series of iterative steps to understand the precise requirements of the project, focus on the correct emphasis for the designs, and use process capability information to predict the outcomes of assembly and design concepts. Design and assembly options can then be compared and improved before production begins.

According to Tecnomatix, eM-Tolmate was selected as the basis of VM because of its strong performance record and maturity as a product. It uses digital engineering models, assembly strategies and process capability data to predict the performance of key product characteristics.

In particular, eM-Tolmate simulations were employed to evaluate the effects of variation on the JSF airframe affordability demonstrations. As a result, changes were made to allow the more accurate location of parts within an assembly. The VM process is also being used by the JSF preferred weapons system team to provide a better understanding of the effect of variation on key assembly characteristics. VM aided in the development of self-locating strategies, which enable workers to assemble parts without using tools. This has resulted in significantly reduced tooling costs.

"VM is a proven process, but with the JSF we're making it even more effective and efficient", said Tom Burbage, executive vice-president and general manager of the Lockheed Martin JSF team. "It is clear that VM is reducing costs on an aircraft that already is setting new standards for manufacturing efficiency."

"Tecnomatix eM-TolMate is a cornerstone of our variation management design method. It has helped us optimise the relationship between customer requirements of the air vehicle and the manufacturing quality of its assemblies", said Randy Schwemmin, advanced affordability initiative manufacturing engineer at Lockheed Martin Aeronautics Company, Fort Worth. "eM-TolMate provides a method to test designs without prototypes. Among the benefits are shortened cycle time and reduced cost. This practice is revolutionising our approach to product design."

The statistical tools and methods that VM brings to the design and production of the JSF are already believed to be benefiting other Lockheed Martin Aeronautics Company programmes. For example, using VM on a design of the forward equipment bay for the F-16 fighter aircraft was considered instrumental in reducing the number of parts required from 90 to 22. In addition, 904 of 1,155 fasteners and 174 of 206 tools were eliminated. Recurring assembly costs were reportedly reduced from $37,500 to $20,900 per unit. Building on the lessons that have been learned from programmes such as the F-16, F-22, F-18, Harrier and Eurofighter, VM is being developed and refined as a JSF team initiative.

Harel Beit-On, president and CEO of Tecnomatix, says: "eM-TolMate was developed to meet the needs of manufacturers such as Lockheed Martin, and we are delighted that it is already providing tangible benefits, including improved product quality and reduced costs and cycle time".

Lockheed Martin received one of two JSF concept demonstration contracts awarded by the US Department of Defense in November 1996. The Lockheed Martin JSF team includes Northrop Grumman and BAE Systems. Lockheed Martin began its flight test programme on October 24, 2000 with the successful first flight of its conventional take off and landing configuration (CTOL), designed primarily for air force use.

The Lockheed Martin X-35 team wrapped up a tremendously successful CTOL flight test programme on November 22, with 27 flights and over 27 hours, achieving a reported 100 per cent of customer objectives, including elements of up and away flying characteristics of the short take off and landing configuration (STOVL). Flight tests of the Navy configuration are set to take place, and the Marine and UK Royal Navy and Royal Air Force version, which will demonstrate the transition phases of STOVL characteristics, set for 2001. A single contractor for the engineering and manufacturing development (EMD) phase will be announced in the second half of 2001.

Details available from: Tecnomatix Technologies Limited. Tel: +44 (0) 121 323 1309; E-mail: kate@tecnomatix.co.uk; Web site: www.tecnomatix.com