munro examples

7/31/2019 Munro Examples

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Presented by

John Hobday / Gareth SaundersLean Engineering Team

Design ExcellenceMunro - Lean Design Examples


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FAT DESIGN

What's wrong with this design ?


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BOEING Waste Pipe Bracket & Wire HarnessDesign Comparison

No. of Assembly Ops.

Parts

Assembly Time

Labor Cost($)

Material Cost($)

Tooling Cost($)

Total Cost($)

Mass

FAT

210

15

46 min.

$35.27

$28.74

--

$64.01

2.1 oz.

.


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LEAN DESIGN


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BOEING Waste Pipe Bracket & Wire harnessDesign Comparison

No. of Assembly Ops.

Parts

Assembly Time

Labor Cost($)

Material Cost($)

Tooling Cost($)

Total Cost($)

Mass

FAT

210

15

46 min.

$35.27

$28.74

--

$64.01

2.1 oz.

LEAN

8

3

1.5 min.

$1.15

$2.44

$14,522

$3.59

0.8 oz.


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LEAN DESIGN


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Change Programs

Do we really need budget and headcount reduction, to reduce costand maximise profit and quality performance ?

Or is there a different way ?

Is there plenty of profit in A/C manufacture which we are unable toexploit?

Design optimisation (simplified designs, part count, assemblytimes etc)

Zero Defects

Right first time design (more rigour in the early design phases,deeper trades and across wider aspects of the design not justweight and performance)


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System Overview

Door Arm

Spring

Anchor Brkt & Bolt Assembly

Upper Mounting

Brkt & Hinge BoltAssembly

Door Plate

Inboard Rib-2

Outboard Rib-2

Datum Surface Rib-2Rib-2

Bay 1-2Bay 2-3

Direction ofingress for

maintenance


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Door Arm

Spring

Anchor Brkt & Bolt Assembly

Upper MountingBrkt & Hinge Bolt

Assembly

Door Plate

BASELINE

Total Build


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Idea 46 - Torsion spring around hinge bolt/shaft of door arm

Spring to be sleeved on the bolt/shaft thatmounts the door arm in the upper clevisbracket. The long side of the spring is

seated in a feature machined into the doorarm. The short side can react the forceagainst the mounting bracket of the door.Both ends of the spring could require asacrificial boot to prevent component wareor fretting.

DeletedItems

Torsion springmounted on hingebolt between the

bracket arms


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Concept Visualisation


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New Door

Pressed or superplastic formed doorplate made from 5083 (Al-Mg-Mn) alloyfriction spot welded to the door arms

Reinforcementfeatures pressedonto door surface

Spot Welds, numberas required.Alternative MIG orTIG weld.

(if not feasible returnto bolted assembly)

Assumed 3500 Engineering Hours to introduce change


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AIRBUS UK LTD. All rights reserved. Confidential andproprietary document.

This document and all information contained herein is the soleproperty of AIRBUS UK LTD. No intellectual property rightsare granted by the delivery of this document or the disclosureof its content. This document shall not be reproduced ordisclosed to a third party without the express written consentof AIRBUS UK LTD. This document and its content shall notbe used for any purpose other than that for which it issupplied.

The statements made herein do not constitute an offer. Theyare based on the mentioned assumptions and are expressedin good faith. Where the supporting grounds for these

statements are not shown, AIRBUS UK LTD will be pleased toexplain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321,A330, A340, A350, A380, A400M are registered trademarks.

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