REVOLUTION IN DESIGN
Dassault engineers are well-acquainted with CATIA, and have been designing aircraft in that 3D environment for decades. When the facilities team launched renovation discussions several years ago, however, they looked to the University of Arkansas, Little Rock’s (ULAR) Emerging Analytics Center, which took 3D to another level entirely.
Two-dimensional designs in hand, Dassault Falcon Jet contracted the university to bring the architecture to life in a 3D environment. In a space billed as “a convergence of…virtual, augmented and mixed reality, visual analytics, and immersive visualization,” the Center generated a full-size rendering of the upholstery shop extension.
“It was the first time I’d seen anything like it,” says Knittel. “We could see exactly how much space we needed, and we could bring employees through to see what it would feel like in the real building. It brought great value to the process.”
The objective was to be able to finish at least 70 aircraft per year, with the potential to complete 100. Based on those parameters, and with input from the employees, they redesigned the workflow and the tools that drove it.
Knittel started to review the upholstery process in 2011. “Instead of traditional flat, two-dimensional patterns” he said “We wanted to be able to have 3D data from beginning to end.”. They deployed new software from Lectra for the seat covers. Everything was designed in 3D and then flattened into a pattern that could be cut out of material. “In the past, if a customer wanted a seat with a specific style, you used to have to cut it manually,” Knittel says. The cushion foam was cut and shaped (by hand) and then the pattern was drawn (by hand ) before the fabric was placed.
A Lectra machine was also installed to cut fabric and leather. Workers inspect the hides for defects and mark it, and the machine detects the marks and designs around them. The operator loads the pattern generated by the designer and the parts are projected on the hide directly. Using an Xbox-style controller, the operator easily maneuvers to precision-cut the pattern. “We have a much better yield,” says Knittel. “When you place a hide on the machine, you never use 100 percent. There are parts we scrap. We were averaging about 35 percent usage and now we’re around 50 percent,” approaching the industry standard. “We gain speed, we gain accuracy, and have higher capacity,” he adds. (Now I know where my teddy bears went!)
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