Signal Lighting User Interface for Aerospace Application


Challenge

Epec was approached by a tier one aerospace supplier to manufacture signal lighting user interface assembly for a private jet airliner. The assembly would be used at each passenger seat for giving instructions during the flight.

Understanding all the customer's requirements, we built and shipped the production run along with the first article required by the PO. Shortly after we got a notification that the entire shipment is being rejected for micro fine scratches which met the customer visual inspection criteria.

After the customer visited our manufacturing facility, it was determined that the inspection process for the customer was different from what we were originally supplied with.

It was concluded that the multiple processing and assembly steps involved with this user interface should have been manufactured and assembled in a clean room environment. We were able to meet the customer's quality requirements and needs without adding significant cost or manufacturing time.


Solution

Our engineering team developed a method to coat the user interface assembly prior to human handling. This coating had to be robust as this component would go through a machining process, screen printing, finial assembly, and packing and shipping. The coating had to hold up to machining fluids and general handling throughout the manufacturing process.

  • Signal Lighting User Interface - Front View
    Signal Lighting User Interface - Front View
  • Signal Lighting User Interface - Back View
    Signal Lighting User Interface - Back View


We researched and identified a spray on coating that was inexpensive and extremely durable and then could be removed by the customer leaving the Class A surface untouched until the customer received the finished product. By identifying this coating we were able to meet the customer's changing needs and not add significant cost.


Result

Based on the suggested process changes presented, the customer's application met the required quality levels that they were expecting.

The cost change to the customer was minimal to the entire user interface assembly. This process change did add one step to our manufacturing process. Timing had to be considered so the manufacturing facility could produce in enough time to meet the customer's ship dates and quantities. During the initial research, time studies were completed to assure tack times could meet manufacturing requirements. These time studies showed positive results and still made it cost effective to produce the product.


High Reliability Human-Machine Interface Solutions
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