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Avro Newsletter:Roll Out of the Avro Arrow

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Rollout, Pg8

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John Wilson of sub-assembly, is seen above fabricating a stainless steel heat exchanger duct.

Quality Control Gains
New Inspection Skills

Quality Control inspectors okay each step of the complex Arrow assembly. Here, final adjustments are made to the starboard wingtip by Wally Grandey, left, and Bill Osborn of assembly.
By Joe King
project such as the Arrow, can owe much of its successful completion to first rate team work and individual enthusiasm of all people concerned with it. These qualities were fully exploited by each man in Quality Control and Inspection, regardless of his position in the scheme of things.
     Quality Control joined in right from the start of the Arrow manufacturing program and there is very little of the preparatory work that they were not concerned with. Back in October of 1954 a group under Norman Turrall became responsible for checking all Arrow drawings before their release to the Shops. His instructions read: "It will be the responsibility of Quality Control to ensure that a part made to the limits of the production drawing or loft will in no way depart from the requirements of the Engineering and Quality Control Departments, the requirements of specifications in force, and the requirements of the R.C.A.F."
     By June of 1957, a total of some 38,000 drawn or lofted parts had been checked and passed through the section, plus some 14,000 parts which had been reworked or redesigned. Competent checking of drawings resulted in a smoother flow of work through the shops with an accompanying reduced number of hold-ups and queries.
One result of this group's work it that a complete breakdown of inspection stages has been available to men on the floor in time for each component, installation, or marry-up sequence. A very important phase of Quality Control operations concerns the Arrow's interchangeability program. Tool designs are routinely checked off for correctness of interchangeability features. When a "first off" part is rejected in the Machine Shop an investigation of the tooling is made to off set the possibility of unnecessary repetition of set ups and tool re-works.

Interchangeability
    
With interchangeability designed into the Arrow Quality Control has played ap important part in its successful application.
     Maurice Cobb, Chairman of the Company Interchangeability Committee, reported in October of 1954 that a start had been made on the Interchangeability Report. That first report of a few pages is today a volume of more than two hundred pages today. To Quality Tool Inspection and others this report is "the bible" since it details fully the tool features to be inspected so that acceptable interchangeable parts and components can be produced by the manufacturing division.

Besides compiling the Interchangeability Report, Maurice Cobb is responsible for devising, setting-up and guiding the Quality Control functions so far mentioned. He also superintends Quality Tool Inspection.
     Consider the significance of the Arrow wing sections going together in the marry-up jig and later in the wing final assembly jig, and again later when the fuselage components and the complete wing went together. These marry-ups indicated a terrifically high degree of jig and jig-reference accuracy. It speaks well of Quality Tool Inspection, that so few snags showed up and that components went to-gether with the ease they did.
     This group under John Trollope passed off the first Arrow jig reference in February, 1955, and the first assembly jig 12 days later. Since then some 235 tools have been passed and 331 jig references, and these include the largest assembly jigs now in the plant. The main concern of Quality Tool Inspection is interchangeability tooling. However, in June of last year they took over the proving of sheet metal press form and stretch forming tools and since then have cleared through some 10,000 tools.

 

Quality Tool Inspection also look after tools which produce classified "complex" machined parts and a variety of other tools which by arrangement with the RCAF can be used as checking media to ensure correctness of the part produced.

Inspection Innovations
   
Using innovations on inspection, such as accepting profile machined ribs and spars off the machine set-up, and machined castings for canopies and windscreens off the production tooling, has playing a big part in speeding production to the point it is today. At the same time it has meant headaches for many.
     Take, for instance, Gordon (Andy) Anderson in Receiving Inspection, who has found his section loaded with many parts which were larger than anything handled before. In many cases Andy's men have had problems in discovering what to inspect the parts with. For example, no surface table of sufficient accuracy was available, so it was necessary to have a 30-foot table re-surfaced to an accuracy of plus and minus .0008 in. A custom made universal angle computor had to be obtained because existing and available equipment was not large enough for Avro's purpose.

Pioneering . . .
    
Evidently the cockpit canopy castings have presented the biggest difficulties, these involved many hours of hand lay-out both before machining and after.
    These castings are made from a magnesium alloy not previously used on this continent and this caused Receiving Inspection to get involved pretty deeply in the pioneering work.
     Dave Couperthwaite and his men in Machine Shop Inspection had to contend with similar problems, but primarily with machined skins and profiled structural parts such as ribs, spars and formers.
     Machined skins produced by the big Kearney and Trecker receive some twelve or more separate inspection operations,
(Continued on Page 11, Col. 4)

Sam Gray is shown at work on an inspection panel on the port outer wing. Detail of Arrow's bogey landing gear can be seen plainly above. Assembly progress is continually checked against drawings. Here in its jig is the front fuselage section showing both cockpits and engine air intakes.

8                                                                                                                                                                                                                        AVRONEWS  

CONTENTS:
Page 1:
Cover Art Work.
Page 2:
Tribute, Proposal To Product, All-Weather Interceptor, Delta Planform.
Page 3:
Go-Ahead, Aerodynamics Tests, Powerplant Changes, Pilot Visibility.
Page 4:
Precision Keynotes All Arrow Tooling, Drawn Full Scale, Travelling Cutter
Page 5:
First Production Arrow Sets Low Manhour Record, From Paper to Hardware.
Page 6 and 7:
Centerfold Art Work.
Page 8:
Quality Control Gains New Inspection Skills, Interchangeability, Inspection Innovations, Pioneering.
Page 9:
Selling New Designs Requires Specialists, Need Test Pilots Aid At Early Design Stage, Set Out Details, Training Aids, Cockpit Layout.
Page 10:
Concept To Completion..., Computer Capacity, Ground Handling, Electronics, Production Prototype, Stress Analysis.....
Page 11:
Low Manhour Record, Sound Control, Outside Suppliers, Coast to Coast, Efficient Handling, New Methods, Bottlenecks, Impact, Quality Control......
Page 12:
Advertising, Tribute, DDP Helpful Partner, Subcontractors, Flight Test Program. Precision Keynotes, Selling New Design

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Scott McArthur.

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