Prototype Aircraft Sub-Assembly Fabrication using Common Stage Walking Line Assembly Model

This paper describes the application of Walking Line Assembly (WLA) in prototype fabrication of yoke sub-assembly and its effectiveness. The technical aspects and challenges involved in development and fabrication of engine mount yoke tube assembly for a civil aircraft are presented. Activities representing reverse engineering process and fabrication of yoke tube are detailed comprehensively. WLA model adopted for this assembly is compared with conventional methods and fixed layouts. Further, WLA model is modified with a common stage set on every process where the expected capability of the task in the shop floor is brought out in consensus with the operational demand and standards. This is achieved with very little disturbance to the existing aircraft fixed line fabrication set up. This model has given encouraging results by expediting the processes and provides an ideal option for building of prototypes in the development stage of an aircraft project.