Advanced Manufacturing for Complex Avionics

The Challenge

GE Aviation approached the MTC for expertise to help them:
• Increase return on capital investments on mixed product portfolios and growing volumes
• Apply modelling, simulation and visualisation techniques to define future states
• Prototype and de-risk new process and equipment solutions off-line
• Transfer capabilities
• Support on-shoring and re-shoring manufacturing through innovations for efficiency improvements

MTC’s Solution

The MTC applied a number of their leading technology themes, including: Electronics Manufacturing, Robotics and Autonomous Systems, Manufacturing Simulation and Advanced Tooling and Fixturing, to address key activities such as:
• Process analysis and developments
• Closing skills and capability gaps
• Facilitating cultural change
• Encouraging a high automation, high integration, high value electronics philosophy
The MTC worked closely in collaboration with GE, OES, SCS and Tannlin.

The Outcome

• Optimised machine and line requirements for machine efficiency
• Guided development concepts and de-risked application
• Generated future state factory models to support scenario planning
• Demonstrated new automated robotic assembly cell for final unit assembly
• State-of-the-art equipment introduced for automated solder joint inspection

Benefits to the Client

• Direct labour productivity has increased year-on-year
• Work in progress reduction over 50% and batch throughput time from seven to two days
• Printed circuit board manufacturing competitive against low cost country options, increasing in-house assembly
• Higher value added per person
• Established a Centre of Excellence for high value, high volume complex manufacture

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