Redesigned Aileron in full production
Saab has developed a redesigned aileron for the Airbus Single Aisle family which in appearance is identical to the older one, but where the costs have been cut by 25 per cent. Recently, the first redesigned aileron was delivered to Airbus UK.
The production of ailerons for the Airbus single aisle-family is a high volume programme for Saab Aerostructures. Saab has developed a redesigned aileron which in appearance is identical to the older one regarding weight and performance, but where the number of components has been halved. Throughput time is considerably shorter and production cost has been reduced by a full 25 per cent. Recently, the first redesigned aileron was delivered to Airbus UK in Broughton.
Pontus Kallén, Senior Vice President and Managing Director, Saab Aerostructures and Rob Campbell, from Airbus UK in front of the new redesigned aileron.
This simplified design, which is adapted to high production volume, has also been steered by production methods. Manufacture now takes place in what is known as pulsed production where there is considerable emphasis on ergonomics, and each workstation has certain tasks to be performed in a set time. Assembly has also been made more efficient through utilisation of an automated production line with fixed stations.
The ailerons are mostly made of composite and all laying-up of the composite material takes place in an automatic tape laying machine which cuts costs for laying-up and reduces material waste.
The aileron is assembled in a completely new pulsed production line. This line has been specially arranged to match the pulsed flow and to provide a good ergonomic workplace. All workstations perform tasks that have been adapted to suit the pulsed movement in assembly line that takes place according to a predetermined time plan. Performance of the various stations has been balanced and optimised to reduce costs and tooling. The number of stations can vary depending on how many units are to be manufactured per time period. The pulse rate is set and balanced to market needs.
The line is similar to those used in the automotive industry, but has been specially designed to suit this particular product. In certain respects this line is more advanced than those employed in automotive production.
Saab Aerostructures has produced ailerons for the Airbus Single Aisle family since 2000, and the first delivery took place in 2001. The ailerons are delivered to Airbus UK in Broughton, Britain for the final wing assembly.
Back to CNB 2/2007