Controlling costs from the design source is an effective measure to implement the "zero defect" management and "get things right the first time" concept, and is particularly important for the aerospace industry. As the first batch of "Six Goods" team of China Aerospace Science and Technology Corporation and the first batch of "Long March Group" of China Carrier Rocket Technology Research Institute, the aircraft structure group bears the responsibility of "helmsman", grasping the course of aircraft structure design and product cost The control project starts here. The team members are determined to forge ahead and work together to study effective strategies to control costs.
Trick one: Strictly control the cost of test pieces
Aircraft design is a complicated process. From development to finalization, it must go through dozens of ground tests and hundreds of ground tests. If the test pieces are produced in full accordance with the official product drawings, it is a great deal of manpower, material and financial resources. waste. However, under the premise of meeting the test requirements, try to optimize the raw materials, structure and test requirements, then the amount of scientific research funds saved will be considerable. For example, a certain model is in a complex state and requires a lot of ground tests. For this, the structural group has found the source and weakness of cost control through statistical analysis. By simplifying the structure of the test piece, selecting low-cost universal raw materials, and the same state of the ground Measures such as repeated use of test pieces save a total of more than 10 million yuan in ground tests before the flight, and provide an effective reference for the cost control of other types of ground test pieces in the future.
Generally, aluminum is used as the material of the aircraft shell, and then it is made into a cone, called aluminum forgings, and the production cycle of aluminum forgings requires at least six months. In order to shorten the production cycle and improve production efficiency, the structure group made the material into another model called aluminum castings without affecting the performance and quality of the product. The production cycle was shortened by about 2 months. During the production process, it was found that due to the large axial length of the shell, the entire production cannot be completed at one time, the production cycle of the product greatly exceeded expectations, and because of the difficulty of machining, the quality of the produced product has more problems. In order to shorten the production cycle and improve the quality and performance of the product, the team has improved the product structure, greatly reduced the processing volume of the product, and increased another processing volume with higher processing efficiency, shortening the processing cycle from 90 days to 45 days. At the same time, because the improved structure is relatively simple, the processing quality of the product can be effectively controlled. These two cost control measures alone reduced costs by more than half a million yuan.
In the batch production process of a new model, a large number of unqualified products appeared, which caused a sudden increase in the production cost of delivered qualified products and seriously affected the production schedule of the product. In order to strictly control product cost and production quality and improve batch production efficiency, the structure group has done a lot of research and analysis work, and found out the reasons for improvement. As a result, the rate of unqualified products has been reduced from 82% to 4%, while greatly reducing The cost of scrapping, repairing, and warehouse management caused by product over tolerance has saved a lot of manpower, material resources, and time, strictly controlled the production cost of the product, and improved the production efficiency and progress of the product.
Trick 2: Pay attention to three and three
Strict "three-level" approval system, adhere to the "three singles" statistics and analysis, and attach importance to the "three" work.
"Three-level" refers to design, proofreading and review. The three-level approval system is a system that the design department must implement when designing products. The structure group organizes relevant personnel to compile the plan approval specifications, and tabulate, standardize and decide Don't let go of any details. For key tasks and key stage drawings, organize old experts to review the drawings. Experts can not only find drawing errors, but also correct the unreasonable design methods of young designers and help young designers grow. After standardized drawing review and expert checks, the quality of the design drawings can be effectively controlled to lay a solid foundation for production.
"Three orders" refers to technical notices, questionnaires, and change orders. As the saying goes, "Forget the past, the teacher of the future", as the design work becomes more complex and increasingly busy, it is almost impossible to make mistakes in the design process. Therefore, it is very important to summarize. The structure group insists on monthly statistical summary of the three orders, holds a team and team quality analysis meeting, introduces all members of the three orders this month, and analyzes the contents of the three orders, thereby reducing the probability of repeated problems and improving the design quality.
"Three transformations" is an important form of standardized design of a system. The implementation of "three transformations" in a system can effectively reduce duplication of labor, save money, improve product quality, shorten development cycles, and reduce development risks. Therefore, it is used by many countries in the world as a basic approach and policy for the development of professional system equipment. Therefore, the team set up a "three modernization" research group, through the cleaning and rectification of existing various aircraft, for the general structural parts, components and structural elements, systematically give their basic type or series type spectrum, summarize and form The "Compilation Manual of Three-Dimensional Design of Common Parts of Aircraft Structure" and "Compilation Manual of Three-Dimensional Design of Aircraft Structure Design Elements".
Trick 3: Upgrade the design method.
The upgrade of design means represented by "3D digitization" is a key way for the development of pilot technology of structural groups. The structural group first applied 3D digital collaborative design technology to the structural design of the aircraft, and realized the integration of overall release, section structural part design, instrument assembly, cable laying, pipeline design, simulation assembly, mechanism simulation, strength calculation, etc. The design has opened up the channels for the digital design and integrated manufacturing of the aircraft structure products of our hospital, which greatly shortened the aircraft assembly time. The application of three-dimensional digital collaboration technology is of great significance for improving product design, manufacturing quality, and assembly efficiency.
Trick four: insist on controlling the whole process
Track the production process, follow the principle of "never let go of any out-of-tolerance products, and never waste any available products", timely analyze and deal with production problems, and minimize the rate of production waste on the premise of ensuring product performance. And the original "5S" design chain concept, each S represents the focus of work in different design stages, in order to effectively control the entire process of product design. The five Ss are SensiTIve, Support, Skilled, SaTIsfied, and Share. They also represent "design problems, analysis problems, problem solving, Five key steps of submitting users and reversing each other are solved. If these five steps are solved, the speed of the entire design chain can be improved and the market competition can be better adapted.
Since 2004, the Structural Design Group has won 11 scientific and technological achievement awards above the ministerial level, more than 30 academic and scientific achievement awards, and declared 22 national defense patents. .
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