Boeing 737 new generation (ng) to 737 max production

LMI AEROSPACE (SONICA GROUP)

Boeing roll out of the 737 max required existing fixtures and manufacturing production tools to work with both NG and new MAX aircrafts

What:

737 NG manufacturing assembly line to implement the addition of the 737 MAX changes. Fixtures, tooling, hardware, training, robot automated drilling arm mount, and inspection changes between the two are to be identified and verified for production.

How:

Use CATIA V5/V6 CAD software to design, fabricate, and update existing fixture(s) to work with both NG and MAX production parts. Sourced out to McMaster, Planet Tooling, High Tech Solutions for quote, lead times, and purchase with installation on the floor.

Results:

Within 5 months, production of the 737 MAX assembly line had 14 large fixture assemblies for the Crewfloor and Nose Wheel Well of the MAX implemented and no late deliveries to the customer. Along with an automated robot arm with updated fixtures and mounts to work with the newly MAX.

Crewfloor drilling template and tooling update

LMI AEROSPACE (SONICA GROUP)

What:

Multiple floor defects from mis-drilled hole sizes, to damaged parts during internal moving caused rushed production to fix and deliver parts on time. Shop/Illustration aids were created to help operators and machinist located and use the correct tooling to

How:

Utilize 3D printing and tool aids to assist production in reducing defects of drilled holes, and damaged shipping units while being moved internally and to the customer. Over 5000 drill holes with 10 different sizes dependent upon fasteners used (rivets or hi-loks).

Results:

Shop aids, illustrations, fastener keys, plastic color coded templates, and 3D printed shipping mount solutions were all implemented and used through production to reduce defects. Hole defects were reduced by 22% over a 2 year period with color coded tooling and templates to aid machinist in manually drilling fastener holes.