Introduction

The airplane and aerospace industry is characterized by the production of highly complex, unique, and high-value products. Each aircraft or spacecraft is often a one-of-a-kind project, requiring meticulous planning, scheduling, and resource management. Traditional mass production techniques are not suitable for this industry due to the uniqueness and complexity of each product. ​ This paper explores the application of project manufacturing concepts, as presented by Mohamed El-Mehalawi, Ph.D., PMP, to the airplane and aerospace industry, focusing on scheduling, sequencing, and resource pooling operations. ​

Project Manufacturing in the Airplane and Aerospace Industry

Project manufacturing, or engineer-to-order (ETO) manufacturing, is particularly relevant to the airplane and aerospace industry. Unlike repetitive manufacturing, which produces standard products in large quantities, project manufacturing involves the creation of unique products tailored to specific customer requirements. ​ This industry requires a different approach to production planning, scheduling, and controls, as each aircraft or spacecraft is a project in itself. ​

Unique Challenges ​

The airplane and aerospace industry faces several unique challenges that make project manufacturing essential:

1. Customer Authority: Customers often have significant input and authority over the design and production process, leading to frequent changes in priorities and specifications. ​
2. Complex Components: The assembly of an aircraft or spacecraft involves a high number of components, each with varying delivery times and specifications. ​
3. Engineering Changes: The industry experiences a significant number of engineering changes throughout the project lifecycle, necessitating a flexible and adaptive scheduling system. ​
4. High Value and Customization: Products in this industry are typically high in value and require customized production routing and resource allocation. ​

Integrating Manufacturing Schedule with Project Schedule ​

One of the primary goals of applying project manufacturing concepts is to integrate the manufacturing schedule with the overall project schedule. ​ This integration provides project managers with greater control over the entire project, including the manufacturing phase. ​ In the airplane and aerospace industry, this integration is crucial due to the complexity and interdependence of various project phases.

Critical Path Method (CPM)

The Critical Path Method (CPM) is a valuable tool for scheduling and managing project manufacturing in the airplane and aerospace industry. By defining the sequence of operations and identifying the critical path, project managers can ensure that all activities are completed on time and within budget. The CPM allows for the creation of a detailed activity list, complete with duration, labor resources, machine resources, and material resources. ​

Example of Activity Sequencing ​

Consider the production of an aircraft wing. The wing assembly involves multiple subassemblies, each requiring specific operations. ​ For instance, the wing spar may need operations such as cutting, drilling, and welding, while the wing skin requires forming and riveting. By using the CPM, the sequence of these operations can be defined, ensuring that each subassembly is completed in the correct order and within the specified timeframe. ​

Resource Loading and Management ​

Effective resource management is critical in the airplane and aerospace industry due to the high value and complexity of the products. The proposed system for project manufacturing provides a methodology for managing and resource loading in production plants dedicated to project manufacturing. ​

Resource Pooling ​

Resource pooling involves combining the demand for resources across multiple projects to optimize resource allocation and utilization. ​ In the airplane and aerospace industry, this approach helps manage the overall load of the manufacturing plant, ensuring that resources such as skilled labor, specialized machinery, and materials are efficiently utilized.

Role-Requirements Histogram ​

A role-requirements histogram can be used to visualize the demand for specific roles, such as milling machinists or welding technicians, across all active projects. ​ This helps managers prepare for peak resource allocation periods and plan for training or reallocating workers to meet demand. ​

Managing Bottlenecks ​

Identifying and managing bottlenecks is essential in the airplane and aerospace industry. High-value machines, such as large milling machines or specialized welding equipment, often represent bottlenecks. By scheduling projects based on the availability of these critical resources, managers can minimize delays and ensure efficient production. ​

Automating Schedule Creation and Updates ​

The proposed system emphasizes the automation of schedule creation and updates, which is particularly beneficial in the airplane and aerospace industry. Automating these processes reduces the time and effort required to generate detailed schedules and ensures accuracy by minimizing human errors. ​

Initial Schedule Generation ​

For each project, a unique routing sheet is developed, detailing the sequence of operations required for each subassembly. ​ By converting these routing sheets into an activity list in the project scheduling software, the initial schedule can be generated quickly and accurately. ​ This process can be automated, allowing for the creation of a resource-loaded schedule in a matter of minutes.

Updating the Schedule ​

In most manufacturing plants, a manufacturing execution system collects real-time information from the shop floor, such as operation start times, labor hours, and material consumption. ​ By integrating this data with the project scheduling system, the schedule can be updated automatically, providing an accurate reflection of project progress and resource utilization. ​

Earned Value Management (EVM) ​

Earned Value Management (EVM) is a powerful tool for measuring project performance and progress. ​ In the airplane and aerospace industry, EVM can be used to track the efficiency of manufacturing processes and identify areas for improvement. By comparing actual performance against the baseline schedule, managers can detect issues early and take corrective actions to ensure project success. ​

Example of EVM Application

Suppose the baseline schedule states that bending 1000 tubes requires 200 labor hours. ​ After 40 hours, only 300 tubes are completed, indicating a problem with process efficiency. ​ By using EVM, managers can identify the issue and implement corrective measures to improve efficiency and stay on schedule. ​

Conclusion

The application of project manufacturing concepts to the airplane and aerospace industry offers significant benefits in terms of scheduling, resource management, and overall project control. By integrating the manufacturing schedule with the project schedule, using the Critical Path Method, and automating schedule creation and updates, the industry can achieve greater efficiency and flexibility. ​ Effective resource pooling and management, combined with Earned Value Management, provide a comprehensive approach to managing the complexities of airplane and aerospace manufacturing. Implementing these concepts can lead to improved project outcomes, reduced costs, and enhanced competitiveness in the industry.