|
 How is the plane
coming???
This page attempts to offer an
answer via the 5 views (sections) below.
If you're new, you may want to start with section # 5) which explains my
status tracking process or jump directly to #2) for photos.
1) Recent Activity
Each week (or so) I'll post a
few key photos from the prior week (below).
Click Here to see an archive of past weekly photo updates.
<< Return to the Top
>>
2) Monthly Activity Summary (& Photo Journal):
Each link below jumps to a page
with photos and a short description of the month's activity.
<< Return to the Top
>>
3) Progress Reporting and Analysis:
Additional progress analysis:
<< add link to trend chart1 >>
<< Return to the Top
>>
4) Detailed Progress Tracking Spreadsheet:
 The link below will call up a PDF file of my recent progress
tracking spreadsheet (or click the image to the right).
Progress Tracking Spreadsheet (PDF)
This spreadsheet is laid-out to track progress as described
in the progress tracking process explanation
further below.
|
NOTE:
you must have the adobe acrobat reader program installed on
your computer to read
PDF files. If you do not have it, you can
download it for free from here
http://www.adobe.com |
<< Return to the Top
>>
5) Progress
Tracking Approach & Process:
How is the plane
coming???
While this seems like a
simple question, there really isn't a simple answer - besides
"fine" or "slow" (grin). There are thousands of parts,
many of which require some degree of trimming, fabrication, or
special attention. Additionally, many items highly
interrelated. When completed, the entire aircraft can be
thought of as one fully integrated piece of equipment. Thus, many
things are done in parallel and most components are
fabricated/fitted, then temporarily removed to facilitate working on
other items, and then each is often re-installed/assembled and
checked again later (multiple times).
Generic Activity Groups
To simplify the planning and progress
tracking process, I've summarized all tasks into the following eight
(8) generic activity groups:
|
Generic Activities |
Task Descriptions |
|
Design |
Since this is a kit, the
"basic structure" and many parts are already
designed. However, several
of the systems are left to the builder to design/build.
Design tasks include:
-
Gathering requirements
(structural & operational);
-
Outlining options, conducting a failure analysis (FMEA);
-
Analyzing alternatives;
-
Selecting the
desired design and validating the decision(s);
-
Defining tolerances & acceptance criteria;
and
-
Updating the documentation.
To see the items
requiring design effort, refer to the detailed progress
PDF spreadsheet above.
|
|
Procurement |
Many of the necessary
parts/pieces are included in the kit. Generally, the
kit includes most items except for:
-
Engine,
propeller/spinner, engine accessories (exhaust, intake,
controls, hoses, probes and sensors, etc);
-
Avionics (flight
instruments, radios, navigation equipment,
backup/standby systems, etc);
-
Electronics (wire,
switches, circuit breakers, lighting, etc);
-
Limited heater
and/or fresh air system components;
-
Upholstery, cloth,
insulation, trim, and "soft" interior/finish items;
-
Paint, data plate,
tow bar handle, exterior finish/trim items.
Form the the items not
included in the kit the procurement tasks include:
-
Identifying the
needed materials, items, and specs;
-
Locating suppliers,
-
Gathering
comparative product and cost data;
-
Selecting
a source;
-
Ordering;
-
Tracking shipping
and confirming
receipt,
-
Verifying
conformance; and
-
Updating documentation.
|
|
Fabrication |
Some parts are supplied
in their 100% final form and thus require little or no
fabrication (such as pre-machined parts, custom weldments,
electrical components, etc). However, many various
other parts are made from raw materials (fiberglass,
aluminum, tubing, etc), or are made from a rough molded
part/shell which require trimming, forming, and/or
pre-assembly, or are made from many small discrete parts
that require pre-assembly. Generally the kit is
designed be built with common hand tools and require little
or no:
-
Weldling;
-
Complex machining
and or metal forming;
-
Plating and/or
surface prep beyond sanding and painting;
-
Heat treating,
tempering, etc.
Fabrication tasks
typically include some combination:
-
Creating
templates/fixtures (as needed);
-
Fabricating the part
(cutting, molding/forming, drilling holes,
bonding/riveting, etc);
-
Preassembly;
-
Validating conformance
to the designed size, spec, weight and function;
-
Rework (when
required); and/or
-
Finishing of
internal parts (paint, lubrication, safety wire, etc);
-
Creating and/or
updating documentation.
|
|
Fit/Trim & Install |
Overall, some parts are
supplied such that they simply bolt together with little
fanfare (e.g. "some assembly required). Typically however,
most parts require some combination of the tasks
listed below to be fit and installed in/on the airplane
(both the prefabricated /final-form parts and the hand
fabricated ones). Note: this is one of the most time
consuming activities in building an airplane (along with the
body work and finishing).
-
Assessing the
desired placement, orientation, fit, and clearance to
other related, nearby, and/or critical items;
-
Modifying and/or
fabricating brackets/attachment points;
-
Selecting the most
appropriate attachment method, fastener, and orientation
(i.e. bolts are generally inserted top down when
feasible);
-
Reviewing any safety
considerations regarding the final placement, fit, and
installation;
-
Reviewing any future
inspection and/or maintenance serviceability
considerations regarding the final placement, fit, and
installation;
-
Trimming and/or re-forming
the part to it's final fit & location;
-
Installation and/or
assembly (bolding, bolting, riveting, etc)
-
Verifying position,
alignment, fit, function, and clearance;
-
Disassemble and
reassemble as necessary;
-
Updating
documentation.
|
|
Final Assembly |
After the parts
have been designed, procured, fabricated, and fit, the last
activity is to put them all together (for the final time).
Depending the nature of each part (permanently attached,
semi-permeate, and/or removable) the final assembly tasks
may include:
-
Surface
preparation;
-
Bonding;
-
Post-cure cleanup;
-
Assembly
(rivet, crimp, and/or and torque to spec, etc);
-
Inspect;
-
Safety wire/seal;
-
Final
verification;
-
Document and update final assembly checklist.
|
|
|
|
|
Body Work |
One of the advantages of
a composite (fiberglass & carbon fiber) airplane is the
ability to create very smooth and aerodynamically efficient
shapes. However, the "cost" of this advantage is
"paid" in the requirement for bodywork. Body working
composite structures entails the following tasks to get the
desired final shape and smoothness:
-
Grinding and Filing;
-
Filling (micro and
flox);
-
Coating (micro and
primer);
-
Sanding;
-
Repeat process as
necessary (grin)
|
|
Finishing |
Following the
tasks above, the final activity is to button it all up and
make it look good. For this project, I define the finishing
activity to include a wide variety of tasks which include:
-
Final primer
and paint (external surfaces);
-
Upholstery,
carpet, and cloth (interior)
-
Labeling and
placards (as required)
-
Verifying
functionality (mechanisms)
-
Paperwork
and documentation (regulations)
One finishing
related consideration is whether to conduct flight testing
before or after final paint and upholstery. There are
advantages and disadvantages of each approach. Since I
am planning on testing prior to final paint and upholstery,
those tasks will be completed following testing.
|
|
Testing |
Testing includes
all activities conducted to verify intended function and
performance; including initial testing of individual
materials and parts, bench testing of systems, ground
testing, and flight testing. As such testing actually
occurs throughout the project. For each phase of
testing, the tasks include:
-
Preparing
testing needs, objectives,
plans & criteria;
-
Setting up
the test;
-
Conducting
the test;
-
Gathering/recording the results;
-
Evaluating
and analyzing the results;
-
Identifying
discrepancies and issues (if any);
-
Investigating issues;
-
Proposing
remedies;
-
Taking
corrective action;
-
Retesting as
required;
-
Updating the
documentation.
|
Progress Tracking Approach:
To create a structured progress tracking
model, I applied each of the generic activities (from above) to my
project information structure (ref:
Intro-project structure page) at the sub-component level.
I use the sub-component level because the "component" level is too
broad (and thus to subjective) for measuring progress; and the "item" level is too
detailed (administratively inefficient). However, the
"component" level is useful for a rolled-up / summarized view and the "item"
level is useful for ensuring accuracy
and completeness of the sub-component progress assessments.
To assess progress, each sub-component is
"scored" for each of the
relevant activities (0= not started, 3= 50%, 6=Done, and NA=not
applicable) and converted to a %. Any % scoring could be used,
I just found this one to be the simplest approach that would work.
A overall "Activity View" of
progress can be created by "rolling-up" the sub-component
progress assessments for each generic activity (i.e. Fabrication is
57% complete).
To get a progress view of a particular subcomponent (across
activities), I apply the following standard weights to each activity
and add-up the scores. The activity weights are somewhat arbitrary, but
directionally correct and ultimately add up to 100% (so if you
benefit early, you pay later). I use three sets of
weighting factors depending on what "view" of progress I'm are interested in.
|
Generic Activities |
"Build" View |
FAA View |
Total View |
|
Research / Design |
20% |
|
15% |
|
Procurement |
10% |
|
5% |
|
Fabrication |
30% |
25% |
20% |
|
Fit /
Trim / Install |
35% |
30% |
25% |
|
Final Assembly |
5% |
5% |
5% |
|
Body Work |
|
30% |
25% |
|
Finishing |
|
10% |
5% |
|
Total |
100 |
100 |
100 |
To create a summarized view
of progress at the component and/or category level (or for the
entire project), the sub-component assessments are "rolled-up" (i.e.
Airframe is 77% complete).
To view my actual progress
tracking sheet (at the sub-component level):
Goto
4) Detailed Progress Tracking Spreadsheet (above)
<< Return to the Top
>>
|
N727RT: Project Notebook
