Sensing, Controls and Automation GroupJune 9-10, 2004.ppt

Sensing, Controls and Automation GroupJune 9-10, 2004 John M. Griffith Technical Fellow Structural Technologies, Prototyping and Quality Phantom Works, St. Louis The Boeing Company Expertise/Background Advanced Composite Materials, Processing and Manufacturing/Quality…….. New Technology Development Technology Maturation Application Transition Associated with Advanced Composites for 38 Years Definitions Technology Developer and Technology Customers Have Significantly Different Perspectives These Metrics Do Not Take Into Account Different Perspectives From Multiple Disciplines Typical Time Frames Going From Initial Development to Production Range From 1 Year to 15-20 Years. Definitions Sensing Directed at Variable Measurement (Directly or Indirectly) Used In-Process and/or Embedded in Parts Control Directed at Variability Areas/Items and Limits Includes Materials, Processing, Indirect/Support Materials, Equipment and Tooling Covers In-Process Control and Final Part Control Used at Three Different Times Initial-Setup Production Changes/Change Control Definitions Automation Relative to Processing/Manufacturing Operations or Steps Preforms (If Applicable) Injection (Material(s) Into Preform or Tool) Secondary Operations Relative to Equipment Established and Available Special Purpose State of The Art (SOTA) Assessment Sensing Tend to Minimize Sensors in Production Tend to Maximize Sensors During Maturation and Startups Temperature and Pressure Primary Variable Sensors Few Qualified For Batch Type of Aerospace Production Several Key Process Variables Not Presently Measurable by Sensors Control Tend to Over Control Everything Through Specifications (Knowns and Known Unknowns) Unknown Unknowns Create Problems 6 Sigma is Helping Control of Change is an Issue Automation Has Been Difficult for Aerospace Composites Liquid Molding Because of Low Rates, Low Quantities and Batch Type of Mfg Previous Focuses Were on Labor Intensive Areas Such As Preform Layup Automation Drive