Cost-oriented process optimisation through variation propagation management for aircraft wing spar assembly

Vincent McKenna, Yan Jin, Adrian Murphy, Michael Morgan, Rao Fu, Xuda Qin, Caroline McClory, Rory Collins, Colm Higgins

Research output: Contribution to journalArticle

1 Citation (Scopus)
115 Downloads (Pure)

Abstract

Overconstrained assemblies such as aircraft sub-assemblies present a challenge to production planners, as variations in parts and processes can make it difficult to achieve all assembly Key Characteristics (KCs) simultaneously. Despite assigning tight tolerances to sub-component manufacture, part variation propagation necessitates expensive and time-consuming variation management processes such as shimming in order to ensure the final assembly is within specification. This paper presents for the first time a variation propagation model for overconstrained assemblies, and develops a novel modelling method to connect variations with production costs. This facilitates a novel process optimisation method based on variation propagation, with the ability to analyse the trade-offs between the cost and achievable variation limits of the entire manufacturing chain in order to minimise the overall manufacturing cost. An overconstrained wing spar assembly is used as a case study to validate the methodology.
Original languageEnglish
Pages (from-to)435-451
JournalRobotics and Computer-Integrated Manufacturing
Volume57
DOIs
Publication statusPublished - 10 Jan 2019

Fingerprint

Process Optimization
Aircraft
Propagation
Costs
Manufacturing
Process Management
Modeling Method
Tolerance
Optimization Methods
Specifications
Trade-offs
Entire
Specification
Minimise
Methodology

Cite this

@article{0144a25511984672b02463b489d29ae0,
title = "Cost-oriented process optimisation through variation propagation management for aircraft wing spar assembly",
abstract = "Overconstrained assemblies such as aircraft sub-assemblies present a challenge to production planners, as variations in parts and processes can make it difficult to achieve all assembly Key Characteristics (KCs) simultaneously. Despite assigning tight tolerances to sub-component manufacture, part variation propagation necessitates expensive and time-consuming variation management processes such as shimming in order to ensure the final assembly is within specification. This paper presents for the first time a variation propagation model for overconstrained assemblies, and develops a novel modelling method to connect variations with production costs. This facilitates a novel process optimisation method based on variation propagation, with the ability to analyse the trade-offs between the cost and achievable variation limits of the entire manufacturing chain in order to minimise the overall manufacturing cost. An overconstrained wing spar assembly is used as a case study to validate the methodology.",
author = "Vincent McKenna and Yan Jin and Adrian Murphy and Michael Morgan and Rao Fu and Xuda Qin and Caroline McClory and Rory Collins and Colm Higgins",
year = "2019",
month = "1",
day = "10",
doi = "10.1016/j.rcim.2018.12.009",
language = "English",
volume = "57",
pages = "435--451",
journal = "Robotics and Computer-Integrated Manufacturing",
issn = "0736-5845",
publisher = "Elsevier Limited",

}

Cost-oriented process optimisation through variation propagation management for aircraft wing spar assembly. / McKenna, Vincent; Jin, Yan; Murphy, Adrian; Morgan, Michael; Fu, Rao; Qin, Xuda; McClory, Caroline; Collins, Rory; Higgins, Colm.

In: Robotics and Computer-Integrated Manufacturing, Vol. 57, 10.01.2019, p. 435-451.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Cost-oriented process optimisation through variation propagation management for aircraft wing spar assembly

AU - McKenna, Vincent

AU - Jin, Yan

AU - Murphy, Adrian

AU - Morgan, Michael

AU - Fu, Rao

AU - Qin, Xuda

AU - McClory, Caroline

AU - Collins, Rory

AU - Higgins, Colm

PY - 2019/1/10

Y1 - 2019/1/10

N2 - Overconstrained assemblies such as aircraft sub-assemblies present a challenge to production planners, as variations in parts and processes can make it difficult to achieve all assembly Key Characteristics (KCs) simultaneously. Despite assigning tight tolerances to sub-component manufacture, part variation propagation necessitates expensive and time-consuming variation management processes such as shimming in order to ensure the final assembly is within specification. This paper presents for the first time a variation propagation model for overconstrained assemblies, and develops a novel modelling method to connect variations with production costs. This facilitates a novel process optimisation method based on variation propagation, with the ability to analyse the trade-offs between the cost and achievable variation limits of the entire manufacturing chain in order to minimise the overall manufacturing cost. An overconstrained wing spar assembly is used as a case study to validate the methodology.

AB - Overconstrained assemblies such as aircraft sub-assemblies present a challenge to production planners, as variations in parts and processes can make it difficult to achieve all assembly Key Characteristics (KCs) simultaneously. Despite assigning tight tolerances to sub-component manufacture, part variation propagation necessitates expensive and time-consuming variation management processes such as shimming in order to ensure the final assembly is within specification. This paper presents for the first time a variation propagation model for overconstrained assemblies, and develops a novel modelling method to connect variations with production costs. This facilitates a novel process optimisation method based on variation propagation, with the ability to analyse the trade-offs between the cost and achievable variation limits of the entire manufacturing chain in order to minimise the overall manufacturing cost. An overconstrained wing spar assembly is used as a case study to validate the methodology.

U2 - 10.1016/j.rcim.2018.12.009

DO - 10.1016/j.rcim.2018.12.009

M3 - Article

VL - 57

SP - 435

EP - 451

JO - Robotics and Computer-Integrated Manufacturing

JF - Robotics and Computer-Integrated Manufacturing

SN - 0736-5845

ER -