A leading global aerospace technology supplier approached ALTEN India to play a pivotal role in ensuring design integrity, integration consistency, and smooth data maturity transitions across its digital product development lifecycle. The objective was to reduce rework, improve design quality, and enable faster progression to be manufacturing by implementing structured Digital Mock-Up (DMU) quality checks.

Quality checks are mandatory to validate the configured Digital Mock-Up (DMU) maturity publications and to approve the release of drawing sets. These checks ensure that all parts fit and function together seamlessly, identifying any design inconsistencies and integration issues early on. By validating 3D models and designs, potential problems can be detected and resolved promptly, thereby reducing costly errors and delays. This process facilitates smooth transitions between design phases, enforces quality gates, and ultimately enhances productivity in the final assembly line.

Challenge:

1. Integration of Designs in Digital Mock-Up (DMU): All aircraft parts must undergo a comprehensive quality check within the DMU to guarantee seamless integration.
2. 3D and DMU Validation: Every 3D design must be thoroughly validated before progressing to the Design Sign-Off (DSO) release stage to prevent downstream issues. 
3. Design Maturity Management:
   • Concept Phase: Initial design concepts must be frozen in the DMU before transitioning to the development stage. 
   • Development Phase: Fully developed designs must be finalized and frozen in the DMU to maintain version control and consistency. 
4. DMU Gates Compliance: Designs must successfully pass through all defined DMU gate stages before release to ensure completeness and integrity. 
5. Cost, Time, and Material Impact: Design non-conformities cause delays and disruptions in the final assembly line, negatively affecting product delivery schedules and cost efficiency. 

Solutions: 

1. Two-Stage Quality Check (QC1 & QC2):
   • QC1: Ensures correct product structure, effectivity, and proper linkages within the DMU.
   • QC2: Identifies and eliminates design non-conformities before manufacturing and assembly.
2. Adherence to Design Principles: Implementation of standard design rules and guidelines ensures consistency, technical accuracy, and alignment with design intent.
3. Design Analysis: Regular review and analysis of 3D models help identify and escalate design issues early to the responsible teams.
4. Design Maturity Tracking: Maturity assessments are conducted during both concept and development phases to verify readiness for the next stage. 
5. DMU Reviews: Structured validation and verification activities detect and resolve design issues prior to final release.
6. Quality Gate Reviews: A formal gate review process ensures all required DMU stages are completed and approved successfully.

Benefits:

• Improved Design Quality: 
  Mandatory QC checks ensure high-quality deliverables before manufacturing. 
• Reduced Integration Errors: 
  QC1 confirms correct structuring and effectivity in the DMU, minimizing upstream errors. 
• Enhanced Manufacturing Efficiency: 
  QC2 ensures a clean handover to production by reducing design-related non-conformities. 
• Increased Assembly Line Productivity: 
  Issue-free designs enable a streamlined and efficient final assembly process. 
• On-Time Delivery and Reduced Rework: 
  Early identification and correction of issues improve project timelines and reduce costs.