Advanced Manufacturing and the F-35 Lightning II

Transcription

1 F-35 Lightning II The Centerpiece for 21 st Century Global Security Advanced Manufacturing and the F-35 Lightning II Dr. Don Kinard, LM Senior Fellow A&D Forum November Lockheed Martin Corporation IMPORTANT NOTICE: A hard copy of this document may not be the document currently in effect. The current version is always the version on the Lockheed Martin network.

2 DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for for public public release; distribution is is unlimited. Approved for for public public release release JSF JSF Lockheed Martin Corporation AERONAUTICS Tactical fighters Tactical and strategic airlift Advanced Development ROTARY & MISSION SYSTEMS Radar and surveillance systems Training and logistics solutions Simulation technologies Sikorsky Helicopter MISSILES & FIRE CONTROL Air and missile defense Fire control and situational awareness Nuclear systems and solutions Energy SPACE SYSTEMS Surveillance and navigation Global communications Human space flight Strategic and defensive systems Lockheed Lockheed Martin Martin Corporation Use or disclosure of the information contained herein is subject to the restrictions of the Cover Page AERODEF Conf_ A&D Forum 2

3 DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for for public public release; distribution is is unlimited. Approved for for public public release release JSF JSF Aeronautics Portfolio Strike and ISR Fighter/Trainer Air Mobility U-2 F-35 CV F-35 CTOL C-130J P-3 UAS F-16 F-35 STOVL C-5 F-22 T-50 Trainer Lockheed Lockheed Martin Martin Corporation Use or disclosure of the information contained herein is subject to the restrictions of the Cover Page AERODEF Conf_ A&D Forum 3

4 Fort Worth Plant History Historic Legacy Aircraft production started in the mile-long facility in 1942 B-24 Liberator B-32 Dominator B-36 Peacemaker B-58 Hustler F-111 Aardvark F-16 Fighting Falcon F-22 Mid-fuselage F-35 Production Commenced in 2004 B-58

5 DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for for public public release; distribution is is unlimited. Approved for for public public release release JSF JSF Aeronautics Production Lines F-35 (FW) 180+ Delivered 130 in Flow 4/Mo Production Rate C-130J (Marietta) In Production Since 1956 ~2500 Delivered Current Rate 2/Mo F-16 (Fort Worth) In Production since Delivered <1/Mo Production Rate Lockheed Lockheed Martin Martin Corporation Use or disclosure of the information contained herein is subject to the restrictions of the Cover Page AERODEF Conf_ A&D Forum 5

6 F-35 Acquisition Strategy

7 Fighter Generations 5 th Generation st Gen st Jets Stealth Technology 2 nd Gen 1955 Supersonic 1st Radar 3 rd Gen 1960 Multi-Role Missiles 4 th Gen LO Treatments Advanced Avionics Guided Weapons Common Attributes Advanced Stealth Sensor Fusion Net Enabled Ops Fighter Performance Adv. Sustainment F-35 Additions Multi-Spectral Sensors Interoperability Weapon Types Modernized Avionics 1966 Night, Non Maneuverable Maneuverable High & Fast Air-Surface Only All Weather Operations th Gen Capabilities & Effectiveness Are Superior To 4th Gen

8 Advanced Stealth Must Be Designed In Internal Fuel Tanks Fixed Array Radar Engine Inlets Full Line-of-Sight Blockage Aligned Edges Reduced Signature Nozzles Internal Stores Carriage Low Observable Seams, RAM Seals Curved Diverterless Inlets, Buried Engine F-35A F-35A F-35B F-35B F-35C 18,250 lb 18,500 13,500 lbs 14,000 19,750 lbs F-35C Composite Structure 20,000 lbs Radar Absorbing Material (RAM) Large Capacity Internal Fuel Tanks Low-Emission Radar and Avionics Aircraft Shaping and Edge Alignment Weapons Carried Internally Fundamental 5 TH Design Features Cannot Be Retrofitted

9 F-35 Mission Systems Coverage AESA/DAS/RWR/EOTS All Integral to the Aircraft (No Pods) Electro-Optical Targeting System Active Electronically Scanned Array (AESA) DAS Apertures RWR Antennae Electronic Support Measures Network Connectivity Data Links SINCGARS Have Quick MADL Emitter Locating

10 The F-35 The Next Generation Difference

11 F-35 Master Schedule As of 20 Mar 2015 CY Low-Rate Initial Production and Multiyear Procurement Planned Production Air Force 1,763 F-35A Dept of Navy 680 F-35B/F-35C International 800-1,500 LRIP 1 (2) LRIP 2 (12) LRIP 3 (17) LRIP 4 (32) LRIP 5 (32) LRIP 6 (36) LRIP 7 (35) LRIP 8 (43) LL LRIP 9 LRIP 10 LRIP 11 FR1 First Flights F-35B F-35A F-35C USMC IOC USAF IOC USN IOC Development DT Flight Test Air System SW Fleet Releases F-35A F-35B 2A F-35C F-35MS 2B 3I 3F Eglin Edwards AF Ops 2 Cherry Point Base Stand-Up Nellis NAS Lemoore Yuma Luke Ogden Beaufort Hill Time Now

12 F-35 Design/Supply Chain Roles NGC Center Fuselage Systems Responsibilities Weapons Bay Door and Drives Arresting Gear Radar IFO Doors (Fokker) BAES Aft Fuselage Vertical Tails Horizontal Tails CV Wing Fold Systems Responsibilities Fuel System Crew Escape Life Support EW System Throttle/Side Stick Flight Control Computer LM FW and LM Palmdale Overall Air Vehicle Edges Wing Fwd Fuselage Mate thru Delivery and Finishes Systems Responsibilities Autonomic Logistics Mission Systems Vehicle Systems Training Systems Team Harnesses (Fokker) Integrated Airframe and Systems Designs

13 JSF International Participation NGC Center Fuselage Turkey LM FW and LM Palmdale Conventional Edges Denmark Norway Netherlands Wings Italy Israel (outer wing boxes) Final Assembly and Check-out Italy Japan BAES Vertical Tails Australia Horizontal Tails Denmark Canada CV Wing Fold Canada Strategic Second Sourcing for Major Subassemblies Capacity and Business Case Driven

14 JSF Factory Layout Wing Structures F-35 Production Fort Worth Forward Coordinate Measurement Machine F-16 Center F-16/F-35 Subassembly AVC F-35 Support (Mezz) Component Staging Forward Structures and Systems F-16 Forward Assembly Machining Wing Structures Phase 1 and 2 Wing Mate Wing Systems Aircraft Mate Final Assembly Aircraft Mate Final Assembly Mate/Wing Systems

15 2016 Lockheed Martin Corporation 15

16 Actions To Achieve Rate Readiness Material Manpower Machine Methods Maturing Now for Rate

17 Flow Manufacturing Lean Implementation F-35 Manufacturing Line Is Configured to Enable Flow to Takt Manufacturing. This Means That Components Move Positions at the Same Frequency as Aircraft are Delivered Wing Box Rail Line Incorporates Overhead Rail System To Create Flow, Drive Standard Work, and Reduce Cost and Span

18 What is the Digital Thread? Form Digital Verification Producibility Hardware/Software Applications Creation Integration Data Re-use Solid Model Part Digital Process Verification Digital Fab (NC Driven) Digital Inspection (Laser Tracker) Training / Maintenance Media Electronic Mock-up Maintenance Simulation Common Digital Data Flow Solid Model Tool Lean Assy Planning Digital Assy (NC Auto Drill) Tech Order Preparation Factory Simulation 265D L/H 265D R/H EL4202EN6-4 EN1182ND6 8 PLCS NS 265D Rapid Product Development Concurrent Engineering Concurrent Engineering Improved Quality Reduction in Changes Validated Producibility Improved Quality Learning for Reduced T1 Tooling Reduction Process Flexibility Improved Quality Automated, Repeatable Processes Consistent, Accurate Source Data

19 Advanced Manufacturing Technologies DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for for public public release; distribution is is unlimited. Approved for for public public release release JSF JSF Fiber Placement Automated Drilling Laser Ultrasonic Inspection Graphical Work Instructions Lockheed Lockheed Martin Martin Corporation Use or disclosure of the information contained herein is subject to the restrictions of the Cover Page NC Aero Conf_ A&D Forum20

20 Methods - Robotic Coating Process Direct Use of the Digital Thread Allows Higher Quality, Tighter Tolerances, Reduced Span, and Lower Cost

21 Work Instruction Optical Projection Using the Digital Thread

22 Methods - Non-Contact Metrology Non-Contact Metrology Could Replace CMM and Allow Rapid Measurement of Fastener Flushness, Gaps, and Mismatches

23 Methods - Use of Portable 3D Data in Production Manufacturing Engineer Quality Assurance Assembly Worker Ease Of Use Wireless Connectivity Current Software Functions Ergonomics Device Management Material Handler Production Control Integrator Delivery of 3D Data to the Mechanics is Enabled by AeroSource

24 Manufacturing Technology At Aeronautics

25 Aircraft Quantity Lot Average Aircraft Price TY12$M DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. Approved for public release JSF F-35A Price (TY$) As of 15 Oct 2014 USAF USDoN International SAR 2013 F-35A With Engine TY$ 250 $ $ $ $ $50 0 Buy Year LRIP 1 LRIP 2 LRIP 3 LRIP 4 LRIP 5 LRIP 6 LRIP 7 LRIP 8 LRIP 9 LRIP 10 LRIP 11 FR1-1 FR1-2 FR1-3 FR1-4 $0 Continuous Focus on Affordability

26 Industry Industry Industry Government Industry Government Industry Government DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. Approved for public release JSF Blueprint for Affordability $85M $85M LM, NGC and BAES Investment Continuing Investment Saves Approximately $1.8 Billion by 2019 Reduces the Cost of an F-35 Jet, by Approximately $10 Million by 2019 F-35 Will Cost Less Than $80 Million per Jet in Then-Year Dollars by 2019 Cost Savings Begin Now and Continue Throughout 25-Year Production Profile Leveraging Ideas From Across the Global Supply Chain

27 Future Affordability So What Are We Doing About it? Additive Manufacturing (EBDM, Electron Beam Direct Manufacturing) Cryo-Machining Projects Increased Automation (hole drilling, material application, inspections, etc.) Structured Light Scanning Inspections and First Article Validation Additional projection applications Tablets, Movies, and 3D visualization deployment Lower Cost Precision Machining Material Flow Implementation (Lean Manufacturing) SCM Initiatives Multi-Year Packaging Best Value Sourcing Technology Insertion Strategic Inventory

28 2015 STOVL IOC Declared! Use or 2016 disclosure Lockheed of the information Martin Corporation contained herein is subject to the restrictions of the Cover Page A&D Forum

29 2016 -Air Force Declares IOC for F-35A!!!

30 2016 Major F-35 Events First F-35A Transatlantic Flight Italy s AL-1 Negotiating both LRIP 9 &10 for Approximately 160 Aircraft F-35 Appearing at RIAT and Farnborough in July DT-III for F-35B and F-35C Sea Trails AF IOC Declaration (August) First Japan Delivery in November First Israel Delivery in December Deliver 45 Jets Worldwide 40 from FW; 5 From Cameri Use or 2016 disclosure Lockheed of the information Martin Corporation contained herein is subject to the restrictions of the Cover Page On-Boarding A&D Forum- 31

31 Questions? 2014 Lockheed Martin Corporation Use or disclosure Use or disclosure of the information of the information contained contained herein is herein subject is to subject the restrictions to the restrictions of the Cover of the Page Cover Page NC Briefing Aero Conf_ Title_Date - 32