Aerospace

The Aerospace Industry encompasses the development and production of aircraft, spacecraft, and related systems. It requires cuttingedge technology and precision engineering.

Implementation of Smart FAI in An Aerotech Manufacturing Company

Company Overview

Industry: Precision Aerospace Component
Company Size: 180+ employees
Location: Selangor, Malaysia
Products/Services: Precision Aerospace Components

Background

An aerotech manufacturing company, a leading producer of precision aerospace components, has established itself as a key supplier to major aerospace companies worldwide. The company’s commitment to high quality and stringent compliance with aerospace standards has driven its growth. However, with increasing production demands and the complexity of aerospace components, the traditional First Article Inspection (FAI) process became a bottleneck, leading to delays and challenges in meeting delivery schedules.

Challenges

Manual Inspection Bottlenecks: The manual ballooning of engineering drawings for FAI was time-consuming, leading to delays in the overall inspection process.
Human Error: The manual process increased the likelihood of errors in identifying and documenting critical dimensions, which could lead to non-compliance with stringent aerospace standards.
High Labor Costs: The extensive manual work required for FAI ballooning resulted in higher labor costs and inefficiencies.
Data Management Issues: Managing and tracking FAI reports and data manually made it difficult to ensure accuracy and consistency across multiple projects.

Solutions

To overcome these challenges, the company implemented Smart FAI (PDF Auto Ballooning Software) to automate and streamline the FAI process.

Implementation Steps:

Assessment and Planning:
- Conducted a detailed analysis of the existing FAI processes to identify inefficiencies and areas for improvement.
- Developed a comprehensive plan to implement the Smart FAI software, focusing on reducing manual tasks and improving accuracy.
Technology Selection:
- Chose Smart FAI software for its ability to automatically balloon engineering drawings, identify critical dimensions, and generate FAI reports.
- Integrated the software with existing quality management systems to ensure seamless data transfer and tracking.
System Integration:
- Integrated Smart FAI with the company’s ERP and quality management systems, enabling real-time data sharing and report generation.
Training & Transition:
- Provided training for the engineering and quality teams to effectively use Smart FAI software.
- Gradually transitioned from manual to automated ballooning, ensuring minimal disruption to ongoing projects.
Continuous Monitoring & Improvement:
- Established a continuous monitoring framework to assess the performance of Smart FAI software and make ongoing improvements.
- Used feedback from the engineering team to refine the process and enhance software functionality.

Results

Reduced Inspection Time: The implementation of Smart FAI reduced the time required for ballooning engineering drawings by 70%, significantly speeding up the FAI process.
Increased Accuracy: The automated process minimized human errors, ensuring that all critical dimensions were accurately identified and documented.
Cost Savings: The company achieved a 25% reduction in labor costs associated with the FAI process due to reduced manual work.
Improved Compliance: The enhanced accuracy and consistency of FAI reports ensured compliance with aerospace standards, reducing the risk of non-conformance.
Enhanced Data Management: The integration with quality management systems allowed for better tracking and management of FAI data, leading to more informed decision-making.

Conclusions

The implementation of Smart FAI transformed the FAI process, leading to significant time savings, improved accuracy, and reduced costs. By leveraging automation, the company enhanced its ability to meet the stringent quality standards of the aerospace industry while maintaining its competitive edge.