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There is a new look coming to the F-35 later in the year! With a sleeker, more uniform coating system, F-35s are saving time in Aircraft Final Finishes (AFF) and saving dollars. The design and new look didn’t happen overnight, but rather was the effort of many people over the last five years.
In 2012, James Thistle came to Fort Worth from F-22 in Marietta as the Production Operations Senior Manager in AFF. He quickly recognized the need for improving the throughput of AFF, which at the time was operating at almost double the scheduled span and cost budgeted for the area. After pitching a potentially significant opportunity to his then-director, Tom Carrubba, now vice president of Aeronautics Quality Transformation and Enterprise Integration, he was able to gain the initial support for changing the engineering design, coatings material and the application process used in AFF.
“What resulted in the end was several days of span time saved in AFF and one of the most positively impactful affordability projects on the F-35 to date. It saves significant hours per unit, defects and rework and improves the aircraft sustainability in the field. It also changes the exterior look of the aircraft to a more uniform coating,” said Carrubba.
“The Aircraft Finishes configuration required the preparation and applications of various materials, which aesthetically appear as jig saw panes of various shades of gray across doors, panels and control surface edges. The manufacturing process to yield a complying product are extremely labor intensive and requires unique skill sets and more so concentrated attention to detail, which meant more labor and processing span in AFF," said Thistle. "Despite the immense efforts amongst the F-35 Finishes organizations, the process often yielded escapes and as a result contributed towards the organizations number one driver for quality defects."
The idea to optimize the process by eliminating multiple masking operations and the need to manually hand spray various top coats by using robotic application during the final top coat application; or “Z13” overcoat as it is more commonly known, was conceived. The project will reduce the cost of an F-35A by $16,000 per aircraft and will save $49 million in the total life of the program.
Chad Wemyss, Delivery Operations Manufacturing Engineering (ME) manager, has been working on the project since picking it up as AFF ME Lead in 2012. “This has been one of the most intense collaboration efforts I’ve taken part in. It has involved several years of testing by the Signature Integration and Materials and Processes (M&P) teams, as well as close teamwork with Production Operations, Finishes Engineering, Sustainment, the Affordability team, the F-35 Program Office and the customer, Joint Program Office (JPO). There have been a lot of stakeholders with different aspects of project inputs and requirements and keeping the whole thing moving forward has been challenging, but also extremely rewarding,” he said. The team kept with it and the results were evident when AF-104, the test aircraft for this project, finished its final coatings in AFF. Implementation of the change is expected in the 2nd quarter of 2017.
