2239. IPD Weight Control and Management Plan for Commercial Aircraft

Paper

Abstract

An effective weight control management process is crucial during the aircraft development phase. Historically, it has been shown that without proper weight control the aircraft weight can grow two to ten percent from program launch to certification. The objective of this plan is to identify weight problems before design release. The plan must have effective weight management from the start of the program. It must implement weight control/weight reduction throughout development and flight test to insure a balanced weight/cost configuration for production. The top level weight commitment is the Specification Manufacturers Empty Weight (MEW) as defined in the Detail Specification. This specification and the Aircraft Baseline Configuration Definition (ABCD) provide the design features that are included in the weight evaluation for the derivation of the MEW. This weight control and management plan has been developed to encompass the basic elements of a traditional weight control plan but had several fundamental improvements over conventional programs. It assumes the commitment of an Integrated Product Development (IPD) process including the use of solid modeling. The plan establishes a ?Must Weigh? level for each Product Center and a requirement to track this weight through the design process. This ?Must Weigh? will also be imposed on the supplier procurement packages within the Product Centers. Suppliers must institute a weight control plan compatible with the IPD plan. It establishes a Weight Control Board staring at Configuration Definition (ABCD approval) and continuing through production. It also establishes a weight reduction/improvement program to offset growth and configuration changes to maintain balanced design, weight, and cost. Finally, the plan establishes a weight status reporting system to compare the Product Center ?Must Weigh? with its current weight.