McDonnell Douglas Helicopter Company FACTORY OF THE FUTURE PROJECT

The McDonnell Douglas Helicopter Company (MDHC) Factory of the Future (FoF) Project relies on transfer of a set of systems to minimize the time and effort required to establish a “state of the art” composites manufacturing center. The Integrated Composite Center (ICC) Program at McDonnell Douglas Aircraft Company (MCAIR) authored these systems using basic concepts and control philosophies expressed by the Integrated Computer-Aided Manufacturing study (ICAM Project 1105) conducted by the Air Force and Aerospace contractors in the early 1980’s. These systems integrate Shop Floor Management processes, spanning all levels of Manufacturing from Factory Level planning systems (Master Scheduling, Material Requirements Planning [MRP], Material/Inventory Control, etc.) to Center Level work center scheduling, paperless planning (including electronic changes), download/upload of Gerber nesting programs and part patterns Dynamic Nesting System (DNS) and Direct Numerical Control (DNC), Quality/Nonconformance activities, including “electronic Part buy-off”, and detailed employee work history. MDHC’s role in ICC is as a “Second Site Demonstration” partner, proving through transfer and installation that ICAM-structured, center-based systems can reduce weapons systems costs.