Producibility Element Highlighted:
Perform a Complexity Analysis
An aircraft panel at Boeing containing numerous gussets, brackets, joints, and rivets was highly labor-intensive to fabricate. While not complex in individual features, the sum of the features created an extremely high-cost item. The IPT determined that the function supplied by this assembly did not justify the current cost. Consequently, the assembly became an opportunity for improvement. Manufacturing research and development personnel conducted a study and determined that a casting could be made that represented the configuration of the sheetmetal assembly and satisfied other conditions such as load requirements. A prototype was made for verification, and the sheetmetal assembly was replaced with the casting. The result was a cheaper and lighter part.