The Development of a Manufacturing Failure Mode Avoidance Framework for Aerospace Manufacturing

Abstract

In order to remain competitive in the global market businesses are under ever increasing pressure to ramp up production rates whilst simultaneously improving cost effectiveness to allow continued profitable growth. This requirement is particularly challenging in high value manufacturing which is characterised by expensive product and manufacturing systems and relatively low production volume. This thesis introduces a method for the design of robust and reliable manufacturing processes through the prevention of identified potential failure modes that is based on the principles of the existing Failure Mode Avoidance framework used for automotive system design. The tools and techniques that exist in the literature are reviewed in order to understand the best practice, and subsequently a Manufacturing Failure Mode Avoidance framework is designed. This framework is demonstrated through two unique case studies conducted in a real life manufacturing environment in order to validate its appropriateness to provide robust countermeasures to failure which will allow right first time manufacture. The outcomes of the implementations are discussed, conclusions drawn and opportunities for further research are provided.