Introduction
Spirit AeroSystems Encountered Two Main Challenges
Spirit AeroSystems, a key player in the commercial aerospace industry, faced significant challenges in their material handling processes, particularly in drilling operations for aircraft wing components. The company sought innovative solutions to improve ergonomics, enhance precision, and boost productivity in manufacturing parts for the Boeing 787 aircraft. With specific objectives to minimize physical strain on operators and reduce scrap and rework, Spirit AeroSystems turned to us and Bosch Rexroth for a customized solution.
Client Background
Located in Tulsa, OK, Spirit AeroSystems is renowned for manufacturing complex structures for the aerospace sector. The company specializes in creating components that require high precision and labor-intensive manufacturing, such as Boeing 787 aircraft wing parts. These operations demand not only precision but also significant consideration of operator ergonomics to maintain productivity and quality.
Challenges Faced
Spirit AeroSystems encountered two main challenges in their manufacturing process:
These issues increased the risk of worker injury and affected the overall quality and throughput of the manufacturing operations.
Solution
We leveraged Bosch Rexroth’s aluminum structural framing and ball rail systems to design and implement customized fixtures for Spirit AeroSystems. These fixtures were adjustable to individual operator preferences, significantly improving ergonomics at the workstation. The solutions included a rotating fixture for the wedge component drilling and a carousel fixture for the cove angle parts, both designed to enhance precision and reduce physical strain.
Implementation Process
The implementation process involved close collaboration between Spirit AeroSystems operators, Pacific Integrated Handling, and Bosch Rexroth. Based on initial sketches from an operator, the team developed a rotating fixture for the wedge component and a carousel for the cove angles. We overcame design and manufacturing challenges through innovative engineering and the application of Rexroth aluminum framing, ensuring the fixtures were both ergonomic and capable of supporting the demands of the drilling operations.
Results Achieved
The custom fixtures led to a significant reduction in rework by 80 percent in the wedge area and improved productivity by 50 percent in the cove angle area. Ergonomic issues were virtually eliminated, and the company experienced substantial improvements in quality, throughput, and worker satisfaction. The return on investment for these projects exceeded the company’s targets, highlighting the success of the collaboration between Spirit AeroSystems, Pacific Integrated Handling, and Bosch Rexroth.
