Lockheed Martin is reducing production costs and streamlining
assembly processes by pre-kitting parts and tools. Foam lined
drawers and tray inserts are being used to protect and organize
tools, parts and equipment. The inserts control the location,
condition and inventory. The kits are also meeting strict FOD
requirements and reducing production hours by assuring that all
tools and parts needed to perform an operation are immediately
available without the need for mechanics to leave their work
areas. Tool and Part kitting applications are currently in use on
the C-130J, C-5M and P-3 programs at Lockheed Martin Marietta,
GA and for Missile Component Assembly at Troy, AL.
The concept of part and tool kitting is not new. Many
manufacturing organizations have experimented with pre-kitting
parts and a few are pre-kitting tools. Kit applications have
consistently reduced labor and demonstrated significant
improvements to the assembly process. Unfortunately, the costs
and time required to create and maintain these kits often
approached or exceeded the savings. However, these conditions
have changed.
New technologies have opened the door to re-evaluate the
development and production costs for both tool and part kits. The
introduction of low cost laser profiling and digital imaging
technology now enables kits to be built faster and more cost-
effectively. Today digital cameras make it possible to quickly
arrange an array of parts or tools on a light table and instantly
capture their shape and position. Advanced image processing
software automates the extraction of the profiles and arrangement
of the components from the digital images. The profile data can
be electronically transferred to a two axis CO2 laser or water-jet
profiler depending on the type of foam being used. The cutouts in
the foam can be profiled at high feed rates and the laser can even
engrave the identity for each component. Once the foam insert
trays are complete the individual tools or parts can be loaded into
the custom profiled foam cavities. Production Control normally
loads the trays with parts at the staging or receiving area and Tool
Control adds tools to the tool kits or drawer inserts. This is where
the savings begin. The inserts for the parts eliminate the need for
bagging, tagging, bubble wrap or interleaving of protective paper –
saving both non-value added materials and the associated labor.
The kits are being used for both new assembly work and for
storage and retention of parts awaiting reassembly (Mod work).
They provide an efficient means to achieve, maintain, and even
accelerate productivity. The kits are increasing productivity and
saving production hours by:
A) Foam inserts immediately show availability and visual
accountability of all parts and tools needed to perform a job for
Production Control, Tool Control and Assembly personnel.
B) Laser marked storage pockets in the inserts provide positive and
proper identification of each part or tool in a kit.
C) Labeled inserts guide Production and Tool Control personnel to
quickly “buildup” and verify proper contents for each kit. Shortages
are avoided by early visual accountability that all parts or tools
needed for an operation are available before delivery to the work
center.
D) Trays filled with parts are delivered to Production without the labor
of wrapping, bagging, interleaving and tagging.(Antistatic foam
eliminates the need for ESD bags)
E) The kits come to Production ready for assembly. None of the labor
intensive bag and tag methods of the past. No need to unwrap just
to verify contents. The presence or absence of any part or tool can
be spotted and identified at a glance.
F) Parts are staged as a kit ready for assembly. No Production time is
wasted looking for parts or tools. They are presented to the user in
clear view. Each part can be easily removed as needed to satisfy
the installation sequence specified in the Assembly Work
Instructions
Digital Data Capture
If Computer Aided Design (CAD) profiles of components are
available, a computer graphic program can be used to automate
the nesting of your components. The graphic program also
generates the cutter path data needed to cut the inserts. Even if
CAD data is not available there is no problem. Simply arrange the
components on the LIS scanner table (shown below). The digital
imaging system will instantaneously capture the profile and
arrangement of your tools, equipment or parts. The system can
be located in your facility to capture the part or tool images
without disruption to the production process. The captured images
are analyzed and converted to line data by ProKits proprietary
software. The line data is electronically transferred to a CO2 laser
or water-jet at your facility or at ProKits.
This patented system makes it possible to meet all your kitting
needs faster and more secure than anyone in the market today.
Continuous availability of your parts, tools or equipment-
The on site data capture processes mean that your parts, tools
and equipment never leave the security of your facility. They
remain available at all times if they should be needed by your
production personnel.
On site support-
To further decrease the throughput time for producing large
quantities of inserts ProKits will install one of their transportable
LIS system (shown below) at your facility for no added cost. The
LIS automates the capture of the profile and arrangement of parts
or tools less than 42 inches long. ProKits will train your operator
or provide on site personnel to operate the patented transportable
digital imaging system.
Line Imaging System
Precision Laser or Water-jet Profiling
Laser profilers custom cut each foam insert or component holder. The
profiles can be cut by your numerically controlled CO2 lasers or by a
ProKits CO2 at your facility or at ProKits facility. The laser cutting process
is fast and smooth with minimal labor. The laser produces a “self healing”
cut resulting in a very tough wear surface unlike the rough and frayed
interface surfaces that often result from the use of sharp blades, hot knifes,
or saws. The water-jet is used to cut the profiles of Anti Static Foam.
Lifetime guarantee-
The smooth, wear resistant interface coupled with the tough foam used for
inserts carries a lifetime warranty. If it fails at any time it will replaced at no
charge.
Examples of current Lockheed Martin application areas are shown
below:
The process was initially designed and implemented for tool storage and
transportation at Lockheed Martin.
Portable Tool Kits-
Portable tool kits with custom cut foam inserts can be
configured in a large variety of soft bags and hard cases to
meet your needs. For example shown here is a soft bag containing four
inserts each protected by a clear plastic cover in use by Aircraft Mechanics
on the C-5M program.
Rollaway or Stationary Drawer nserts
Tool Control storage cabinets with foam inserts are used throughout the
Aircraft FOD Tool Control areas of Lockheed Martin Marietta, GA. They
provide for immediate visual tool inventory at the beginning and end of
each shift.
The tool kit storage process was expanded for storage of kitted parts.
Part Kits Ready for Assembly –
The processes developed for tool
storage and accountability have now been expanded to include part kitting.
Nomenclature and instructions can be laser etched at each location or
applied as placards to the insert.
Storage of Removed Parts –
C5-M engines parts are removed and then kitted for temporary storage and
subsequent replacement. During maintenance and repair of large scale or
critical military equipment, removed parts or components must be
inventoried and stored in a manner which assures that each piece can be
reassembled or installed in its original location.
Anti Static Foam Inserts
Photo (at left above) depicts a typical tray holder containing 16 individual
holders. Each holder (photo at right above) has a clear see through cover
and is identified by the step number corresponding to its assembly
operation sequence. The profiles in this foam are produced on the water-
jet.
The holders are loaded with screws, washers and hardware at the supply
point and made ready for assembly. The Step Holders and trays display the
hardware as one unit ready for immediate assembly. This eliminates
handling and removal of the loose hardware from the anti-static bags.
The bags are no longer discarded as waste. They are now recycled to the
vendor for reuse. Three trays are used for each assembly step- one on the
line, one ready for use and one being loaded at the
hardware storage area.
Large Part Shadowboards –
Shadowboards are used for storage of large or outsized parts or tools.
Shown here are tubes awaiting installation. Rather than inserts the
components are held in place with small foam lined brackets similar to a
collection of gun racks. Note that a full size photo forms the background or
shadow of each tube providing an accurate visual cue for proper
placement. We have recently developed a large gantry digital capture
system to scan long or outsized parts,
tools or equipment.
Transportation or Reusable Shipping Cases-
Cases similar to the ones shown above are also being used for:
- Field Service part or special kits
- Valuable or Fragile equipment
- Sales or demonstration display cases
As you can see from this brief overview the equipment, processes, and
systems needed to build the best foam insert kits are available and proven
in multiple Lockheed Martin facilities.
The tool and part kits shown above were produced by ProKits Sourcing Inc.
They have achieved unmatched delivery schedules while maintaining the
highest quality standards. They achieved this standard of performance by
developing streamlined processes built around a unique data capture
system, automated data analysis software, numerically controlled laser
cutting equipment and a team dedicated to support Lockheed Martin.
For more detailed information or a demonstration at your facility contact:
Ray Hill, President and CEO
ProKits Sourcing Inc.
4368 Floridatown Rd.
Pace Fl 32571
Toll Free 877-444-5487
Cell 850-525-8410
Office 850- 995-1920
Fax: 850-995-1911
https://prokits.net