Case Study – Boeing

Our client was challenged to redesign their existing product on a very tight schedule and reduce the recurring costs 50%. With the first unit scheduled to be installed in a specific, new Boeing aircraft our client contracted with us to perform the design and to provide two dip brazed prototypes and six production cast aluminum units.

The DFDAU, a 6MCU ARINC 600, data acquisition and control unit is located in the avionics bay of the Boeing 767 aircraft.

We started with a detailed budgetary analysis of the various manufacturing alternatives to allow us to select the one with the lowest recurring manufacturing and labor cost. We took responsibility for all mechanical design, thermal and dynamic analysis, detail/assembly drawings and vendor contracting and interface.We coordinated the selection of the prototype and manufacturing vendors and oversaw the production of the first eight articles. We also conducted flow bench testing and supervised the QUAL testing of the unit for our client.

In total, we met the rigorous schedule and delivered a product that bettered recurring cost targets, allowing our client to significantly expand its once shaky market position.