Approximately 70% of Avcorp’s direct workforce is involved in the assembly of various aircraft structures. These structures range from 50 to 2,000 manhours per unit, with rates from as low as one to two per month up to 30 units per month. Currently, structures are assembled for four different customers, each with specific quality process requirements. Structures are typically built in smaller sub‑assemblies and then final assembled in a number of positions based on the production rate. An assembly “pulse” line is often used to sequence the precise timing of when structures are moved from one line position to the next. New programs are subject to learning curves, which can result in significant 20 to 30% reductions in hours during the first year of a program and subsequent yearly reductions of 10 to15%. Structures are shipped by truck on special shipping fixtures directly to customers’ assembly lines, where they are integrated into the final assembly of the specific aircraft.

Avcorp makes extensive use of visual management systems, standard work packages and assembly data sheets (ADS) to drive quality, learning curve and ongoing productivity improvements on both new and mature programs. The efficient flow of parts from both internal fabrication operations and the supply chain, which often number 500-1,000 items per unit, is a key driver in meeting quality, delivery and cost targets.

Assembly systems integration	ADS Assembly Data Sheet