Kaman Helps to Power the A-10
Problem: The U.S. war fighters need close air support that only an aircraft like the A-10 Warthog can provide. The problem is that the aircraft was first designed and produced in the 1970’s and has seen increased usage over the years so that they are in need of wing replacements to keep them flying. The other problem is that the aircraft have been out of production since the 1980’s.
Boeing DSS won the program from the U.S. Air Force to manufacture new wings for 242 aircraft in the field. Boeing also had the role to update the legacy drawings and modernize manufacturing techniques. Boeing turned to Kaman Aerostructures in 2008 to support them by restarting the production of the inboard and outboard flaps, the slats, and the decelerons.
Solution: Kaman Aerostructures worked with Boeing to restart production of new and improved control surfaces for the A-10 Attack Aircraft Wing replacement program. Boeing engineers created MBD data from the legacy 2D drawings (first design in the 1970’s) for Kaman Aerostructures to make new tools (working with Kaman Tooling Limited), create new work instructions and new and improved fabrication/assembly methods, manufacture (1,200 detail parts) and source (300 parts) detail parts, conduct final assembly, install wiring harnesses and actuators, and first article inspections on the inboard and outboard flaps, slats, and decelerons. All work was conducted at Kaman Aerostructures Jacksonville.
Tools: Program management, SCM, schedules, MBD data, advanced inspection techniques, manpower staffing and training, teaming with other Kaman Aerospace divisions such as Kaman Helicopters and Kaman Tooling Ltd., visual work instructions on the floor using MBD data.
Results: Kaman Aerostructures is currently on schedule and produced the first assemblies on-time to support Boeing’s wing manufacturing work. Kaman Aerostructures also completed all interchangeability requirements on the program.