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Projects

Solving difficult problems with precision engineering and quality service

Ahead-of-schedule delivery for a complex solution

Pratt & Whitney

Efficiency improvements

Sikorsky Aircraft Corporation · MedEvac Cockpit Nose

Adding capabilities to meet customer needs

Boeing Military Helicopter Division (CH-47)

Pratt & Whitney

Ahead-of-schedule delivery

VECCO Sterling Heights

The Problem

A customer had a need for parts with a complex and hard to manufacture internal drilled hole. The diameter of the bore to access the feature was only 4.13″, and the requirement on size and location was ±.0005 diameter and .003 True Position.

Our Solution

VECCO’s engineers retrofitted the customer’s 5-axis machine with a custom-engineered solution that allowed them to simulate another axis via a “ram extension”. Using in-house 3D printing technology, VECCO designed and prototyped the solution and delivered the complex part ahead of schedule.

Milestones

  • Full-scale replica in 2 weeks
  • Robust manufacturing design in 4 weeks
  • Final delivery ahead of schedule
  • Project delivered on budget

Sikorsky Aircraft Corporation

Efficiency improvements

VAERO Jacksonville

The Problem

Our machine shop encountered several inefficiencies machining several parts for Sikorsky Aircraft Corporation, which provide support for the forward nose equipment and instrumentation. These inefficiencies include slow / long cycle time, excessive tool changes and lack of adequate part documentation for setup. With existing NC programming, an excessive quantity of tools were being used, generating unnecessary tool changes, as well as having total spindle cycle time greater than 6 hours per piece.

Our Solution

Through the use of CAD/CAM software, MasterCam, the team successfully reduced the total quantity of tools used, resulting in a 22% reduction in total tool change time, as well as a spindle time reduction of 25% from original cycle time. During this reprogramming effort, the team also properly defined stock preparation and position through CNC Setup Sheets for continued use by Machine Shop personnel. These changes improved first pass yield to 100% for these items, and eliminated broken tools — further extending the life of our cutting tools.

Boeing Military Helicopter Division (CH-47)

Adding capabilities

VECCO Wichita

The Problem

Boeing’s processing requirements dictated that copper straps be grit blasted and sulfuric acid pickling processing, with adhesive primer application approved to D210-12502-1 only. Due to shrinking industry demand there were no longer any processors qualified on D1-4426 to Boeing’s specifications. An existing processor was found and agreed to become Boeing Qualified, however during the initial review the processor rescinded their offer and Vecco was left without a supplier. To meet customer needs, Vecco determined the best path forward was to add the capability in-house.

Our Solution

Despite it being a chemical processing operation outside the normal composites work performed by Vecco Wichita, we reviewed the specification and understood that the critical feature was primer application at 0.1 to 0.4 mils. We evaluated what would be needed and built a plan with the customer to add this capability to our scope. This required purchasing and approval of chemical tanks and a racking system. After a few months of preparation, qualification was achieved in only 3 days with Boeing on-site.

Milestones

  • Engineering review
  • Process & procedures created
  • Sourcing of equipment and supplies
  • R&D
  • First Article
  • Customer approval