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© 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

The F-35 Lightning II – Focused on Affordability

Dr. Don A. Kinard

LM Senior Fellow

Deputy, F-35 Fighter Production System

NC Aerospace Suppliers Conference

August 2012



STOVL Carrier Trials


F-35A F-35B F-35C


Economies of Commonality and Scale

Key Tenets Counters Current and Future Threats

An Effective Coalition Lower Life-Cycle Costs

Global Security Industrial Cooperation


F-35 Design/Supply Chain Roles

Integrated Airframe and Systems Designs

NGC

Center Fuselage

Systems Responsibilities

Weapons Bay Door and Drives

Arresting Gear

Radar

IFO Doors (Fokker)

BAES

Aft Fuselage

Vertical Tails

Horizontal Tails

CV Wing Fold


Fuel System

Crew Escape

Life Support

EW System

Throttle/Side Stick

Flight Control Computer

LM FW and LM Palmdale

Overall Air Vehicle

Edges

Wing

Fwd Fuselage

Mate thru Delivery and Finishes


Autonomic Logistics

Mission Systems

Vehicle Systems

Training Systems

Team Harnesses (Fokker)


F-35 Major International Production Plan

BAES

Vertical Tails

• Australia

Horizontal Tails

• Denmark

• Canada

CV Wing Fold

• Canada

NGC

Center Fuselage

• Turkey

LM FW and LM Palmdale

Conventional Edges

• Denmark

• Norway

• Netherlands

Wing

• Italy

Final Assembly and Check-out

• Italy

Strategic Second Sourcing for Major Subassemblies

Capacity and Business Case Driven


Contracts Overview

Current Aircraft Production

Aircraft in Ground Test

and Flight Ops

SDD (18 A/C)

LRIP 1 (2 A/C)

LRIP 2 (12 A/C)

LRIP 1 (2 A/C)

LRIP 2 (12 A/C)

LRIP 3 (17 A/C)

SDD (19 A/C)

In FW Assembly

LRIP 4 (32 A/C)

Rolled Out

LRIP 3 (11 A/C)

BF-5 at Pax

AF-9 at Eglin

Delivered to Test site or Base

LRIP 5 (30 A/C)

On Order


Transforming Manufacturing Processes

042111- 8

AeroDef © 2011 Lockheed Martin Aeronautics Company DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.


X-Plane “Craft” Production F-16 “Mass” Production F-22 Lean Production System

F-35 Fighter Production System

F-35 Fighter Production System Evolution

BAE Systems Northrop Grumman Lockheed Martin


Global Suppliers People (Performance)

Designing a Lean and Integrated F-35 Production System

Tooling and Facilities

Product Design

Processes and Systems


Digital Thread Throughout Life-Cycle

Design

Development

Support,

Maintain

and

Train

Build

Test

Program

Management


STOVL 7085 Aluminum FS 496 Bulkhead

Forging and Finished Part

Weight/Cost Trades Drove Material/Structural Selections


F-35 Fort Worth Factory Transition


Macro Material Flow Capability and Vision

FMF / SC&D Overview and Benefits

Engineering Supply Chain

Network

Inbound

LogisticsSource of Repair

Information

Financial

Material Warehousing Production Sustainment

Factory Flow SC&D

Supplier Collaboration & Development Assembly Operations

Demonstrated consumption-based

replenishment system with harnesses

in the J240 work cell

Implemented part-presentation and

harness sub-assembly improvements

for use on manufacturing line

Re-sequenced crew plan to improve

work flow and reduce span time

Improved integration with planning

process to enhance management

visibility into production status

The FMF and SC&D teams are architecting the entire supply chain to support production requirements

by better integrating suppliers, logistics, warehousing and production to meet 1/day rates

Warehouse Flow Center

Reduced number of touches to pick

and kit parts

Minimized idle time between process

steps, excessive motion, and

unnecessary transportation

N

Receiving Shipping

Oth

er

Gov’t

Wing Staging F

F

Sta

gin

g

M&F Staging


New Automation Technologies at NGC

• Inlet Robotic Duct Drilling (IDRD)

– Robotic System Guided by

Laser Metrology System

• Automated Guided Vehicles (AGV)

– Automated Transportation of

Components from Station to

Station.

• Automated Drilling Systems (ADS)

– Highly Accurate Gantry Component

Drilling System (including

Interchangeable Hole Patterns)


430 Assembly Extension 1 430 Empennage Pulse Line Layout

430 Aft Fuselage Pulse line Pulse Line System

BAE Flow Based Assembly Pulse Line Concept


Robotic Coating Process

Higher Quality, Reduced Span, Lower Cost


Automated Drilling

Laser Ultrasonic Inspection GraphicalWork Instructions

Fiber Placement

Advanced Manufacturing Technologies


Laser Projection of Materials and Decals



Work Instruction Optical Projection

Using the Digital Thread

042111- 27


F-35 Learning Curve

300,000

250,000

200,000

150,000

100,000

50,000

0

Labor

Hours

SDD LRIP 2 L1 LRIP 3

Assembly Direct Touch Labor

CV

CTOL

STOVL

F-35 STOVL 61%

F-35 CTOL 69%

LM Legacy 69%

Learning Curve

World-Class Learning Curve Producing 3 Variants on a Common Line

042111- 28


Future Affordability

So What Are We Doing About it?

• Additive Manufacturing of Titanium

• Laser & Cryo Machining Projects

• Automation (Lasers, Robotics)

• Lower Cost Precision Machining

• Application of Lessons Learned

– SDD to Production

– Phase 3 EMAS

– Final Assembly Improvements

• SCM Initiatives

– Multi-Year Packaging

– Best Value Sourcing

– Technology Insertion


Summary

• Transitioning the Fort Worth Final Assembly

Factory

– From F-16 State of the Art to F-35 State of the Future

• Build and Transition a Global Supply Chain

– Exploit the Digital Thread

– Attack the Cost Drivers

– Design for Precision Manufacturing

– Implement Automation and Motion Based Processes

– Enforce the Best Value Economic Model

– Share Supply Chain Risk

• Capture Economies of Commonality and Scale


FYI - Current NC Supplier Base

10 suppliers

589 direct and indirect jobs

$44.5 million in economic impact.

Questions?

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