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Lockheed Martin Tactical Aircraft Systems has integrated the eMPower quality software solution from Tecnomatix Technologies, Inc. to test the dimensional specs of it aircraft assemblies.

Aircraft manufacturer Lockhheed Martin's Tactical Aircraft Systems unit (LMTAS; Fort Worth, TX) was researching alternatives to its existing tolerance analysis procedures. Specifically, it was looking to reduce unit recurring costs, expand user understanding of the assembly process, and improve quality on some of its fighter aircraft. The company turned to Tecnomatix Technologies (Herzliya, Israel), a leader in digital factory solutions and computer-aided production engineering.

The LMTAS unit selected Tecnomatix eMPower Quality software for the preliminary design phase of new fighter programs to test assembly designs for dimensional performance. When it compared the eMPower Quality Assembly package to other tolerance management products, the aircraft maker was impressed with the level of maturity of the software and its relative ease of use.

Before using the Tecnomatix eMPower Quality software, though, Lockheed Martin's manufacturing engineers would occasionally perform time-consuming and labor intensive rudimentary, linear worst-case tolerance calculations. And since choosing eMPower Quality Assembly, the manufacturer has been pleased with the customized support and services Tecnomatix has offered through a series of technical service agreements.

Testing and Validation
The eMPower Quality tools are designed to define, predict, measure, and analyze tolerances throughout the industrial process. It helps ensure that tolerances are correctly specified during the design phase and fully adhered to during the manufacturing and assembly. At every stage, the appropriate tools provide a dedicated solution to minimize variations, reduce engineering changes, and help ensure that parts are manufactured according to the designer's intent.

The software uses a 3D electronic image of a part's tolerance zone, called softgage, to define and store specified tolerances for a manufactured part. The image is stored within the master CAD model and is used throughout the process. With the master CAD model, users can define tolerances, predict the effect of tolerances and the sequence on the assembly processes, create offline inspection programs, measure components on a CMM or NC machine, and analyze measured data against design specifications.

The eMPower Quality Assembly module is the foundation of the LMTAS Variation Management design method. "We have used eMPower Quality to test and validate assembly concepts for our Joint Strike Fighter demonstration articles and for the Preferred Weapon System Concept Design," said Randy Schwemmin, Advanced Affordability Initiative manufacturing engineer at Lockheed Martin. "We are pleased that we have found such a reliable and intuitive tool that helps us virtually optimize the relationship between the customer requirements of the air vehicle and the manufacturing quality of its assemblies."

Across-the-Board Advantages
The aircraft maker has reaped many benefits from using the eMPower Quality software packages. Chief among them are reduced recurring costs and improved aircraft quality. According to Schwemmin, significant improvements were realized when the company used the Assembly solution in its Variation Management design method in an alternative design of the F-16 forward equipment bay.

"The part count was reduced from 90 to 22, the fasteners count was reduced from 1,155 to 251, the tool count was reduced from 206 to 32, and that recurring assembly cost was reduced from $37,500 to $20,900 per unit," explained Schwemmin. "eMPower Quality provides us with a method for testing designs without prototypes, cutting cycle time and cost. It also gives us practice in creating design-build-inspect-improve process cycles that use only digital data. This practice will revolutionize our approach to product design."

For more information on eMPower Quality solutions, contact Tecnomatix Technologies Ltd., 39810 Grand River Ave., Ste. 10, Novi, MI 48375-2108. Tel: 248-471-6140.

Edited by Nancy Katz