Chevron choose Chiron for Airbus cargo door kits
Chevron choose Chiron for Airbus cargo door kits
Keywords Airbus,Cargo doors, Chevron, Chiron
Subcontractors Chevron Aerospace Engineering use Chiron production centres to manufacture more than 60 per cent of the 5,000 parts in the Airbus cargo door kits, which they supply to British Aerospace Aviation Services' Airbus Manufacturing Division at Filton,near Bristol.
Launched in 1996, BAe's programme for the conversion of older Airbus A300B4 passenger aircraft into 45 tonne capacity freight carriers involves the addition of a 3.5m-wide, top-hinged cargo door occupying a quarter of the circumference of the fuselage, between the front port side passenger door and the port wing leading edge. This requires the fitting of upper and lower cargo door surrounds and the door itself, as well as modifications to the cabin floor, air-conditioning and other electrical circuits and the removal and re-skinning of one passenger door and most cabin windows.
Two planes were converted and delivered in 1997, the first going to Bournemouth-based freight carrier Channel Express. However, another 12 have so far been scheduled for 1998 and US leasing specialists C-S Aviation Services have placed orders or taken options for a total of 31 aircraft. With more than 180 of the marque in service and likely to be traded in against newer models, the potential for ongoing regular business is clear!
While FSI of Seattle provided the requisite design expertise, British Aerospace Aerostructures, now Airbus Manufacturing, won the manufacturing work for the conversion in competitive tendering, and in turn selected Chevron as a supplier of many crucial components.
Established in 1984, in a Nottingham industrial unit, since greatly extended, subcontractor Chevron recently opened a new factory at nearby Mansfield and last year acquired Newlands Engineering (now Chevron Aerostructures) at Ilford, near London. These autonomous business units have different but overlapping specialisms: Nottingham is entirely devoted to machining while Ilford's structural assembly work involves both machining and fabrication. A common management team provides a unifying strategy.
Besides Airbus, Chevron has McDonnell Douglas, Westland, Rolls-Royce and De Havilland among its clients."Some customers still ask us what capacity we have: others know that if they tell us what they need, we will make sure we have it!" explains manufacturing director Haydn Martin. "Our customer-based philosophy depends on reacting quickly to their needs," says Haydn. "For example, last December we won an order for stringers for the Airbus A330/340 series, to be machined from extrusions. Chiron Werke UK, Leamington Spa, specialists in high-speed machining centres,provided a machine within one week and we made the first deliveries a week later. We now have a dedicated Airbus wing components cell, producing stringers,spars and ribs.
"In another example, in February of this year, a customer delivered the fixtures and tooling for an urgent job to our factory one Saturday morning and we completed the order the following Monday!"
The combination of structural stresses and the need to minimise weight means that many aircraft parts must be machined from solid, rather than forged or fabricated, to conform to materials requirements. Typical materials are aluminium, titanium and nimonics, in the form of extrusions, plate, bar, castings or forgings, so that fast, accurate and reliable machine tools are central to success in the sector.
Plate 7 The Chiron FZ22L production centre, as supplied to Chevron Aerospace Engineering
Chevron bought its first two Chiron machine tools in 1996, a further six in 1997 and has, so far,installed one of five more proposed for this year. Intended to replace old plant and/or provide extra capacity, the Chirons have been variously allocated to all three factories (Plate 7).
"Our latest purchase was to replace some 1988-vintage Kitamuras", recalls Haydn. "In competition with another supplier, Chiron gave good sales support and were able to offer us greater productivity with fewer machines. Speed and flexibility are crucial and our experience shows that Chirons have the edge over traditional CNC machines,with quick set-ups, high spindle speeds and high feed rates for minimal cycle times. In many ways, they are more akin to automotive industry practice."
Batch sizes at Chevron are usually small: 20 per month is a typical call-off rate. But the variety and complexity of parts can be enormous, as the Airbus cargo door contract shows.
"In a business like ours,where JIT is the rule, we cannot afford unplanned downtime", concludes Haydn Martin. "Fortunately, Chiron's service back-up, both routine and emergency, has been all we could ask."
The aerospace industry as a whole is enjoying a period of expansion, but Chevron is expanding even faster,thanks to its commitment to customer service and rapid response and a willingness to invest in the latest technology. Like Chiron.
For further details contact Chiron Werke UK Ltd. Tel: +44 (0) 990 99 4433; Fax: +44 (0) 1926 33 4404.
