New Airplane Model - Secondary Structure Commonality
This project aimed to introduce new concept designs to standardize some of the unique secondary structures of a new wide-body jet. This type of aircraft structure encompasses components that secure system lines such as wire bundles, fuel lines, and hydraulic tubes, as opposed to primary structures like the fuselage and wings that carry the aircraft's primary loads.
Lizzie Lee effectively project-managed all coordination of efforts across multiple international teams. The project encompassed requirements assessment, feasibility studies, conceptual design, rigorous testing, and standardized part-numbering.
By introducing common design elements, this approach resulted in significant cost reduction, simplified maintenance, enhanced reliability, and streamlining of parts fabrication and assembly.
20+
Key Partner Organizations
5
Countries
4
Continents
7%
Planning Phase Duration
Project in Numbers
Client
Large-Scale Systems Integration at Aerospace Company
Challenge
A new wide-body jet, where the design and procurement of its unique secondary structure were managed by different fuselage partners.
During the design phase of a new model iteration, potential improvements emerged to achieve --as much as possible-- commonality in the secondary structure. These enhancements aimed to reduce part numbers, simplify parts fabrication and procurement, and streamline assembly on the production line.
This effort required modifications to some partners' unique bracket designs. Each partner remained responsible for adapting to the new designs and managing procurement and installation within their respective sections of the aircraft.
This new architecture needed to account for its implications on the aircraft's weight, fabrication processes, supply chain logistics, manufacturing engineering, and installation.
The key partner organizations involved encompassed teams across the world.
Program Management, Systems Integration, Lead Design, Materials, Structures, Weight, Fabrication, Supply Chain, Quality, Test, Certification, Manufacturing Engineering, and Production in the US.
Design teams and partners in Russia, Japan, Italy, and the US.
The overarching objective was to redefine the system architecture, foster partner alignment and agreement, and finalize the secondary structure concepts, material evaluation and selection, design, testing, certification, and manufacturing of the new configuration.
Impact
The impact of introducing commonality of certain elements in an airplane extended beyond mere streamlining of design and procurement processes. It brought about several additional benefits:
Cost Reduction: By reducing the number of unique parts and streamlining procurement and fabrication processes, there was significant potential for cost savings. Commonality lead to economies of scale in production and reduced overhead costs associated with managing multiple unique components.
Simplified Maintenance: Commonality in design meant fewer types of parts needed to be stocked for maintenance purposes. This simplified inventory management and reduced the logistical burden of maintaining a diverse range of spare parts. Maintenance crews benefitted from standardized procedures and familiarized themselves with common components, leading to more efficient operations and maintenance practices.
Enhanced Reliability: Common components underwent rigorous testing and certification processes, ensuring that they met stringent safety and performance standards. This standardized approach enhanced the reliability and predictability of the aircraft's systems, reducing the likelihood of unexpected failures.
Results
Comprehensive Documentation: Developed a comprehensive guide detailing the design, procurement, and installation processes associated with common components.
Effective Communication: Disseminated communications across all partners to ensure alignment and understanding of the benefits and implementation procedures related to common components.
Implemented new secondary support structure for the new derivative.
Extended the use of the guidance for other models and programs.