Role Overview

An opportunity for an Industrial Engineer to get involved with an exciting Research and technology project to develop pylon attachment concepts on existing and future Airbus Aircraft. The role will involve a mixture of design for manufacture assessments, tooling studies and assessments of value stream maps. This role would suit an experienced tooling design Engineer willing to learn Industrial analysis methodologies or could be divided into a number of individual roles according to existing skill sets. Where quantities of activities are specified this would represent the maximum number of solutions, it is expected that some solutions may not need as much effort as others and some may be descoped entirely, in this instance it would be expected to further enrich the remaining concepts to a higher level of detail.

This role is broken up in to 4 activities:

Activity 1 - Value Stream Mapping

Support the development of the 3 value stream maps. The value stream map will provide the build concept and philosophy for the assembly of the pylon options. During this activity you will be required to read, work content trackers and Standard operating instructions to understand STV times for industrial processes. Assembly philosophies for new concepts will need to be dissected to understand methods for new designs. It is also possible to demonstrate modeling within the 3DX platform using a PPR approach if the candidate possesses the relevant experience.

Deliverables

• 7x value stream maps with estimated timings and any impacts on industrial lead times
• Build philosophy presentations showing assembly methods illustrating the sequence of component assembly

Skill Set

Essential

• * Previous experience of creation of build concepts and build networks and establish work content values (with some specific support)
• An ability to read SOI's & work content trackers to understand process times
• Generation of value stream maps in presentation format
• A willingness to visit manufacturing facilities in Broughton to understand the current manufacturing processes

Desirable

• Basic DMU interrogation skills
• Experience with SAP to interrogate routings and timings
• Experience of Simbal toolset for creation of VSMs
• Awareness of Ticon timings and how they are generated
• Experience of 3DX process modelling using a PPR approach

Activity 2 - Tolerance Analysis

This activity will involve supporting the generation of manufacturing tolerances to feed into the broader top level tolerancing assessment for the Pylon to Wing attachment. The candidate should be familiar with Aerospace manufacturing techniques to be able to make reasonable recommendations for typical tolerances. An ability to understand how Datums are derived and their impact onto the overall tolerancing outlook will be essential. The candidate should also be able to understand how the build sequence will change the overall effect on the tolerances at a wing level.

This activity will involve generating a tolerance stack for a future pylon concept using 2 approaches. Top down starting with the performance requirement for the Engine positioning and deriving component tolerance requirements and bottom up using typical tolerances achievable by manufacturing and working up to an attainment value for the engine position.

An expected output will be to contribute to the Engineering activity to generate an interface stack and an Interface control document (ICD) in the format of either a drawing / presentation.

Deliverables

• 7 x 1D tolerance stacks in a spreadsheet format
• Supporting documentation to illustrate the components of the 1D stack
• 5 x Mecha-master models of the down selected solutions (if the candidate has suitable experience)

Skill Set

Essential

• Demonstrated and applied experience of generating 1D stack based tolerances
• Fluent understanding of GD&T application on Aero-structures
• Ability to read Aerospace drawings to extract tolerances
• Knowledge of Aerospace assembly methods and their associated processes such as part to part, shear fastening tension fastening & drilled on assembly
• Understanding of Datum structures and the impact of the Wing Assembly

Activity 3 - Industrial Architecture

This activity will involve proposing build sequences and undertaking detailed design studies to understand constraints for assembly processes. The task will be a continual process with feedback into the design team to influence decisions and to highlight industrial drivers throughout the design evolution. This candidate should be a good communicator both verbally and in presentation format. The role will also involve an appreciation of the tolerancing process to ensure that the build and assembly process supports the attainment of tolerances.

Once assembly sequences have been devised this candidate should be able to liaise with the VSM team.

An important aspect of this role is to be able to steer the tooling concepts to deliver the correct datum and assembly tolerances for a number of concepts each with their own nuances depending on the product and pylon concepts selected.

Outputs will take the form of concise presentations so presenting a clear but measured message will be key. This role will also include the generation and documentation of industrial requirements capture so the candidate should be familiar with generating sound industrial requirements.

A DFMEA should also be created for 5 of the designs to highlight areas of risk, and a risk management approach should be maintained throughout the project.

Line boring investigation

This project is developing a research project to eradicate the need for line boring on Wing pylon interfaces. A number of concepts have been created, each concept should be evaluated for manufacturing capability and evaluated against known tolerance data. A strong design and manufacturing awareness of metallics will be essential. An openness to exploring Research and technology approaches will be important and a proactive approach to investigating new opportunities will beneficial.

Deliverables

• Generation of 7 build concept presentations showing build concepts
• Creation of Process model in 3DX - some training could be provided to support this task

Skill Set

Essential

• Practical experience of deriving build sequences and understanding the appropriate assembly methods
• An ability to select datum features and understand their relevance
• An appreciation of developing new process's or working in an R&T environment

Desirable

• Tooling design experience to guide the conceptual design
• Basic DMU skills for generating build sequences
• PPR Modelling in 3DX for showing the build process

Activity 4 - Tooling Conceptual Design

This activity will involve assessing and creating tooling concepts for new Pylon Wing attachment concepts on both existing and new products. This activity will involve working in both Catia V5 and 3DX although training on 3DX can be provided. At the beginning of the project tooling concepts will be rough in nature and should be able to be modelled quickly and with little concern of the details, these concepts should evolve throughout the project as the maturity of the product increases. The models will be used for assessment of costs and to perform ergonomic and manual handling assessments (where appropriate).

Assessment of impacts to existing tooling may also need to be assessed by overlaying product concept models. Integration of current build / lineside machinery.

Deliverables

• Phase one - Tooling for 7 new design concepts for assembly jigs, Logistics and handling devices and assembly aids (where required)
• Phase two - Tooling for 7 Concepts showing material types and basic sizing of Jigs.
• Basic Tolerance studies showing component tolerance's of tooling based around the requirements provided (see Activity 2)
• Ergonomic assessment of any new tooling solutions if they interact with humans or require any manual handling

Skill Set
Essential

• Conceptual modelling skills in Cat V5 & 3DX (or a willingness to learn)
• Experience of designing Jigs & tooling
• Appreciation of manual handling & ergonomics requirements

Desirable

• Human factor modelling experience for Ergonomic studies
• Knowledge of the A350 Industrial system for Wings or a willingness to travel to Broughton to familiarise with it
• Ability to perform basic hand calculations for the sizing of tooling
• Understand and have a working knowledge of the latest manufacturing and machining techniques and have an ability to interpret concepts from R&T