Process Development for the In-house Manufacture of Aircraft Cabin and Cargo Composite Panels

Mishandling of luggage while it is being loaded into the aircraft cargo compartments, as well as wear and tear of the various panels in the cabin and cargo compartments can result in the aircraft being grounded, with serious loss of revenue to the operator. Delays can be considerable, since ready-made replacement panels from the supplier can take days to arrive at their final destination, and due to the very high prices of these panels and the very large variety which exist it is not economically feasible to stock the panels. This work explores the feasibility of manufacturing replacement cargo liner panels, and cabin and cargo floor panels, in-house and on demand in the aircraft maintenance facility. The panels are grouped into part families, and reconfigurable specialized jigs are designed for the manufacture of panels within each family. A feasibility study shows that in addition to avoiding delays, this strategy can result in cost savings of up to 30% for panel replacement.