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valves would be bulky and production
would be critically reliant on machining
practices.
The Airbus A380’s and Boeing 787’s
hydraulic valves are therefore made from
titanium. However, titanium is much
harder to machine than aluminium.
Cutting speed is often constrained, heat
builds up quickly and vibration can also
be a problem: not good news for any
manufacturing process.
Once again, GE Aviation is partnering
with other specialists, in this case the
machine and tool manufacturers and
AMRC (Advanced Manufacturing
Research Centre – part of Sheffield
University). The partnership has created
specialist monitoring and control systems
that allow running speeds to be set
higher than normal. In addition this
is further enabled through the use of
specific machine upgrades and choice
of coolants. The result: cycle times are
significantly improved upon previously
understood limits.
Also aiding manufacture of the valves
is GE Aviation’s use of Single Minute
Exchange of Die (SMED) – which
minimises changeover time as it allows
operators to change tooling whilst
machines are running.
SMED also allows batch sizes and
inventory to be reduced, in keeping with
lean practices. A number of strategies
were used which, in combination, provide
set-up and change-over times dramatically
lower than those previously realised.
Cycle time
Billets are prepared and loaded outside
of machine cycle time. Finished parts
are also dealt with outside of cycle, and
all elements of the change process are
facilitated with rapid action systems and
mechanisms to further reduce time and
manual interactions.
An intelligent tooling system and
features within the machines and tool
suites ensure maximum tool swaps within
machine time cycles. In addition this
system provides error proofing (‘poke
yoke’) in that the incorrect tools cannot
be fitted.
Titanium provides other advantages
for product concepts and as a result
GE Aviation has created multi-function
hydraulic valve concepts bringing
further challenges to the manufacturing
environment. These products have such
high value that the whole approach to
manufacturing must ensure very capable
processes and thus very high right-firsttime
figures.
As a result the whole extended
GE project team applied latest
methodologies of design for manufacture
(DFM) and advanced quality planning to
ensure this outcome. In support of this
approach the team ensured that the inprocess
and CMM-based technologies
available were fully embedded into
the control plans for the products to
maintain capability.
The latest system requirements of the
aircraft manufacturers and the flow down
of these into the landing gear systems in
which GE specialises created significant
challenges to the manufacturing
programme teams.
Through close-working partnerships,
the leverage of the latest technologies
and the application of the latest
management methodologies, GE
Aviation has taken these manufacturing
challenges and turned them into
competitive advantages. The result is
highly optimised functional products
providing optimum weight with the
ability to supply customer requirements
in a true lean manufacturing
environment. ❙
www.geae.com
Supporting manufacturing | Automated CMM technologies
Acquisition
GE Aviation acquired UK-based supplier
of integrated systems for aircraft
manufacturers and components for
engine builders earlier this year for
$4.8 billion. The acquisition broadens
GE’s offerings for aviation customers
by adding Smiths innovative flight
management systems, electrical power
management, mechanical actuation
systems and airborne platform
computing systems to GE’s growing
commercial and military aircraft engines
and services.
AEROSPACEMANUFACTURING 17

Copyright © 2007 – American Flight Airways – All Rights Reserved. 1
American Flight Airways
OPERATIONS MANUAL v2.0
November 28, 1996
Revised February 17, 2007
Original content by: John Valencia and Kenric Smith
Revised by: Wasim Ahmed & Thomas Snoeck
Copyright © 2007 – American Flight Airways – All Rights Reserved. 2
CONTENTS
1. The Story behind American Flight Airways Virtual Airlines .................................................3
2. Requirements for membership ............................................................................................4
　
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