Dassault Falcon Jet’s Kansas-based Little Rock facility is a fusion of ultra-modern technology, coupled with traditional highly-skilled practices.
Not only has the French airframer had a challenge on its hands to create the latest generation bizjet, it also has had a great deal of work to do bringing its workforce up to speed. Christian Sasso, Little Rock’s general manager says, “the industrial process had to keep up with the technological development. At the same time there was a need to increase production whilst retaining the quality of the product. The solution was to increase our buildings, hangars, workforce and tools. We also had to implement the product lifecycle management (PLM) process.”
He continues, “the first advantage is that as we do the PLM, we start from the specification. We create a very accurate virtual model, and from that we know what we have to do in manufacturing. With a full digital model of the specification we can expect that when we build a cabinet and wiring, for example, the digital model will be compliant with the aircraft.”
That said, Sasso is keen to point out that only basic processes and substructures will be automated. “One of our customers was horrified when he heard we were industrialising and asked ‘does that mean I won’t get my haute couture aircraft? Am I paying for a ready to wear at the same price?’ This is not at all what we’re doing. We don’t industrialise everything – only the substructure, the assembly of the cabinet, the bracketry – what is behind what the customer sees. We will continue to keep the highly skilled craftsmen for the demanding skills that give the aircraft its quality.”
Dassault also now uses PLM on the Falcon 900 and 2000EX and says it has delivered “three or four” aircraft using the process, and that most of its 2007 output will use PLM. There are seven Falcon 7X aircraft in Little Rock. The first one will go out at the end of June, with a further nine due before year-end.
Forecast rate of deliveries from the plant this year is 70 in 2007, ramping up to 95 in 2008. To cater for the growth Dassault is looking to expand the 700,000 sqft (65,032 sqm) factory, mainly in its operational areas and warehousing. There are three paint booths on site, with a new paint booth planned and extra hangars built to accommodate the 7X.
Source: Flight Daily News
