Manufacture of a complex sheetmetal fabrication part for aircraft engines, that requires the assembly of 32 child parts of multiple raw material such as nickel, stainless steel & cobalt alloys (hi-temp alloys)
High number of welding at various conditions and stages (550 Spot welding, 38 GTAW welding),
Multiple stages of Non-Destructive Testing (NDT) inspection (Fluorescent penetrant inspection and Radiography inspection) for GTAW welding
Intermittent brazing and heat treatment operation
Detailed concept of tooling to archive complex profile and quick assembly time
Avalon approached the project with a thorough input study, gap analysis and identification of potential failures as per customer blueprint requirements. The team created a detailed process design that included:
Creation of a Process flow diagram
Stage-wise manufacturing process consisting of individual part, sub-assembly, and assembly with process-controlled tools with poke yoke mechanism
Stage-wise inspection gauges to control CTQ
Control plan linking manufacturing process step to critical inspection
Complete welding cell, training, and qualifying a welding operator
Establishing and qualifying source for brazing and heat treatment process
- Created the first FAI in six months
- Successfully delivered 2000 units in one year.
- Developed complex engine sheet metal fabrication facility with NADCAP certification