UWE Bristol Engineering showcase 2015

Student Name: Ben Gordon
Student Number: 08970917
Module Number: UFMFX8-30-3
Supervisor Name: R. Stamp
Award: BSc (Hons) Engineering
Date: 16 th April 2015
Investigation title: Feasibility of implementing Angle Based Tightening tools onto JSF 3BSM assembly line
Introduction
The highly respected Harrier Jump Jet is
nearing the end of its programme and is being
replaced by the new Short take off and
vertical landing aircraft the Joint Strike
Fighter, the replacement aircraft has a swivel
exhaust duct for hover and vertical take-off.
This exhaust duct uses new technology and
materials to make the product versatile and
light weight. Rolls-Royce plc has identified
the Joint Strike Fighter 3 Bearing Swivel
Module exhaust duct with high costs as a
potential new benefactor for this new
technology and cost saving. However,
introduction of these complex tools into the
aerospace assembly environment has
particular challenges; the volumes are low,
and the product highly complex, with a high
degree of design definition and assembly
standards to adhere to.
As a result, Rolls-Royce plc has chosen Joint
Strike Fighter 3 Bearing Swivel Module as a
pilot project for the new Angle Based
Tightening wrenches to be implemented on.
Bluetooth safety & security
Investigation Objectives
The aims of this investigation are:
• Investigate market leading tightening methods.
• Analysis and mitigation of any operational differences
between wired and wireless tools.
• Investigate the impact on existing staff and consider
how is best to address the culture change.
• Recommend tool location within the existing factory
layout.
• Investigate Operational strengths and weaknesses of
Angle Based Tightening
• Calculate the business benefit and cost savings.
• Implement Angle Based Tightening onto the Joint
Strike Fighter 3 Bearing Swivel Module production
assembly line and prove capability and verify with a
First Article Inspection Report.
• Manage the project in order to deliver a successful and
relevant conclusion within the Rolls-Royce agreed
project time frame, as depicted in the project Gantt
chart and document in a report whilst adhering to
University timescales.
‘LIVE’
MEASUREMENT &
DATA CAPTURE
Project Summary
It is crucial for Rolls-Royce plc to recognise,
develop and utilise new technology in order
to maintain its competitive edge and industryrenowned
high standard of quality, whilst
simultaneously achieving hi quality. In doing
so, a reduction in build times can be extracted
along with additional cost savings, resulting
in a more competitive product – especially in
today’s harsh global financial and business
climate. This is why wireless Angle Based
Tightening wrenches or ‘ABT Wrench’s’ (as
they are termed within Rolls-Royce plc) are
being investigated, and ultimately a
replacement for the current Intellifast
wrenches used today at Rolls-Royce plc
Bristol.
Conclusion
The data collected during the first production
Angle Based Tightening build was marginally
better than expected and presented no
surprises. It was best suited for there to be a
trolley for the equipment so it can be wheeled
to each work station when needed on
assembly, this set of tooling has led to a
40.60% reduction in operations for the flange
tightening processes, which equates to a
reduction of 60 hours per build and a total
cost saving of £85,530.00 whilst increasing
efficiency, quality and repeatability, this
saving could potentially rise to £99,750.00.