CompositesWorld
Issue link: https://cw.epubxp.com/i/576646
OCTOBER 2015 78 CompositesWorld WORK IN PROGRESS By Ginger Gardiner / Senior Editor Israel Aerospace Industries ramps production while reducing costs and improving quality, thanks to integrated optimization software. Optimizing composite aerostructures production ยป A globally recognized military and commercial aerospace and defense company, Israel Aerospace Industries (IAI, Tel Aviv, Israel) is simultaneously a Tier 2 supplier (e.g., to Alenia, for the Boeing 787 program) and a Tier 1 supplier to OEMs, such as Lockheed Martin, Boeing and Gulfstream. For the Boeing 787 program, IAI's Commercial Aircraft, Group Aero-Assemblies Div. produces a variety of carbon and glass fber prepreg aerostructures . Two years ago, as IAI prepared for Boeing's planned production ramp-up to 10 787 aircraft per month, the company was looking for ways to maintain favorable fnancial performance during an economic downturn and increase its competitive position in the global aerostructures market. Increasing output on the 787 program while reducing cost ofered an excellent opportunity, but would also present a challenge. "We looked everywhere for how to cut costs, and then we saw our waste and raw materials," recalls Avishay Hod, composite deputy director for IAI's Group Aero Assemblies Div. "We buy very expensive raw materials and then cut these to form composite aircraft structures, so there is a lot of waste." Already aware of Plataine Technologies' (Waltham, MA, US and Tel Aviv, Israel) composite cut-planning optimization software (see "Learn More," p. 81), IAI sought more than optimized nesting. Plataine suggested its Total Production Optimization (TPO) software, and the two companies began implementing a system that would, by early 2014, not only cut raw material consumption by 5% but also automate daily production plans for materials and cutting, greatly reducing manual tasks and improving materials utilization. Automation has freed up resources and reduced the Cost-competitive aerostructures from composites As a globally recognized manu- facturer of composite structures for commercial aircraft, including pivot bulkheads (top left) and door surrounds (lower left), Israel Aerospace Industries (Tel Aviv, Israel) must continually improve its production processes to maintain cost-competitiveness. Source | Israel Aerospace Industries