Tombstones, Plates Aid Increased Aero Productivity

In the Wichita, KS facility of Bombardier Aerospace, Bombardier Learjet Models 40, 45, and 60 business jets are produced. When Drew Hanus, methods engineer, had a project requiring increased productivity, he turned to Advanced Machine & Engineering (AME) for assistance. He was already familiar with their products and had previous experience with AME. Dietmar Goellner, CEO of AME and Alvin Goellner, fixturing group product manager along with Jim Park, AME's representative in Wichita, visited Hanus at the Kansas facility.

Bombardier was running 240 different parts through a cell comprised of four horizontal, 4-axis machines with a 28-pallet system and one vertical, 5-axis machine with an 8-pallet system.

AME's team of experts demonstrated the advantages of sub-plates with hardened precision bushings and hardened threaded inserts on a 2" grid system. Hanus needed to change parts quickly from one setup to the next. It was shown that grid tombstones and plates along with modular components, would allow him to locate and very accurately and quickly align on a 2" precision grid system.

Hanus purchased several full-grid tombstones to be used with their palletized system along with sub-plates, components, and precision dowel screws – which can be used for locating fixture plates onto tombstones or their pallets for quick changeover.

Grid tombstones and plates along with modular components, allow users to very accurately and quickly locate and align on a 2" precision grid system.

Bombardier's pallets were shipped to AME, where they incorporated bushings, threaded inserts, and locating and mounting holes. A 2" grid system was integrated into their pallets and all was inspected with AME's CMM machine. Calibration blocks were added to check the probe for repeatability of the machines. At the beginning of each day, it shows where adjustments are needed to hold 0.0002" accuracy. A rotary axis check is also done on the fourth axis rotary table to ensure accuracy.

Today, 800 different parts are being run through two cells. Monolithic parts are run on one setup. Bombardier is enjoying a 91% savings on setup time with a total saving of 81% on cycle time over the old dedicated system.

"The new system played a major role in allowing us to achieve our Six Sigma goals for this segment of our fabrication process," says Hanus. "We now have improved setup time, we are producing better quality parts, and we are saving money in the long run."

Advanced Machine & Engineering
Rockford, IL
ame.com

Bombardier Aerospace
Wichita, KS
bombardier.com