Engine _Assembly_Consulting

Axiam provides a review of shop assembly activities for rotating parts and static parts to optimize shop activities in support of productivity improvement, minimal engine vibration and engine assembly repeatability. Axiam's expertise in engine assembly was developed through many years experience with various engine lines and visits to many overhaul shops throughout the world. Axiam will work with the customer's engineers and the engine OEM representative to establish standards for component parts and assemblies at critical points in the engine shop that impact engine assembly.

Typically, some of the areas addressed include:

Shop Practices

Inspection & Assembly Resources
Parts Inspection vs. Throughput
Parts Cleaning
Module Staging
Materials Flow
Parts Overspray
Parts Out-of-Tolerance (part rejects)
Parts Heating
Standards for Parts Tolerance
Overhead Hoist

Vibration Analysis

Variable Management
Data Tracking
Re-inspection Procedure for Rejected Modules
Bearing Housing Assembly
Shaft Mating Process
Rotor Assembly Process
Tooling Variables

Axiam provides a review of shop assembly activities for rotating parts and static parts to optimize shop activities in support of the highest possible productivity and engine assembly repeatability. Working together with customer and engine manufacturer representatives, new build standards are implemented that result in high quality engines and repeatable assembly processes. As a result, the shop will consistently produce engines with the lowest possible vibration characteristics.

Organization

Assemble Team:

Axiam: Engineers

Customer: Engineering, Quality Control & Manufacturing

OEM: On-Site Representative

Define Team Objectives

Typical Objectives:

Reduce engine vibration to .5 mils
Eliminate test cell rejects due to vibration
Eliminate bearing failures
Reduce/Eliminate oil seal leakage/coking
Reduce operating costs by 10%
Reduce spares inventory by 25%

Rotating Parts

Isolate Vibration to Specific Modules

Review test cell & balance data
Examine vibration level variance among engines - inconsistent assembly

Component Fits & Clearances

Review parts measurement techniques
Measurement tool accuracy vs. parts tolerance

Parts Cleanliness

Review parts cleaning & transport process

Parts Temperature for Assembly

Measure parts temperature at setup
Determine maximum time for assembly

Modify Present Assembly Process for Repeatability

Review Assembly Procedures
Review Assembly Tooling

Shop Material Flow

Review flow of component parts to the assembly area for consistent orderliness & good parts

Improve Assembly Process Accuracy

Measure parts with Axiam gauge
Use Axiam software to build model

Review Present Assembly Process for Repeatability

Review assembly procedures, assembly tooling & stacking methodology

Review Balance Machine Accuracy & Repeatability

Review balance machine tooling for introduction of variables

Demonstrate Relationship: Assembly Straightness to Test Cell Vibration

Compare assembly straightness, rotor balance & engine test cell vibration

Establish Final Assembly Straightness Tolerances

Input previous activities

Update Build Standards

Write new assembly manuals

Install Axiam Repeatable Processes

Processes developed concurrently by Axiam

Train Shop Personnel

Hands-on training to achieve accuracy & repeatability

Repeat Exercise on All Remaining Rotating Modules

Static Structure

Review Casing Measurement Techniques

Gauging tools accuracy vs. parts tolerances

Comparison of Bearing Housing Assembly Centerline vs Casing Flange Centerline

Measure Centerline Deviation of bearing housing and casing flange
Check seal plates on shaft for perpendicularity

Develop a Software Stack Model from Casing Module Measurements

Review stack for straightness & bearing alignment

Develop a Software Stack Model from Bearing Module Measurements

Review stack for seal plate perpendicularity

Establish Bearing Alignment Tolerances

Review full engine casing assembly for bearing centerline alignment

Updated Assembly Manuals

Updates for build standards

Training

Hands-on training to achieve accuracy & repeatability

Module to Module

Optimal Orientation ("Best Fit") of Modules

Modules measurement from verification step used to compute optimal orientation for high & low sides

Mate Rotors to Shafts and/or Rotors

Use shaft measurements, rotor measurements & ShaftMate™ software

Assembly Manuals

Assembly Manuals with updated build standards

Operator Training

Hands-on training at site to achieve accuracy & repeatability

Maintaining Repeatability

Optimized Management of Your Assembly Process

Technical Service & Support:

24-hr. Support
Priority Service
Planned Annual Refurbishment
Annual Calibration & Re certification
Software Upgrades & Updates
Annual Refresher Training

Ongoing Engineering Support

Continual Communication