FastKAP Automated Fastener Kitting and Preparation System

Systems and Materials Research Corporation (SMRC) is developing FastKAP, an automated Fastener Kitting and Preparation system that will reduce span times for F-35 fastener installations by as much as 60% by performing most, if not all, fastener identification, collection, and preparation steps offline. FastKAP comprises automated subsystems for kitting, cleaning, and adhesion promoter application. These processes are taken out of the critical path to be completed prior to, and independent of, fastener preparation and installation steps performed at the work cell, significantly streamlining current practices. Electroimpact, a world leader in automated aircraft assembly technologies and SMRC"s transition partner in delivering FastKAP to F-35 primes (and beyond), will adapt off-the-shelf components to engineer an automated kitting system that loads fasteners into a library, reads a factory database-generated requirements list, and pulls the required parts. SMRC will deliver a conceptual design for automated cleaning and adhesion promotion modules, as well as techniques to extend the lifetime of promoted surfaces, with an ultimate goal of delivering kits of pre-cleaned and pre-promoted fasteners to the work cell"just-in-time", ready to seal and install. Phase I focuses on demonstrating functionality of individual FastKAP system components, plus developing initial cost estimates and manufacturing/transition plans. BENEFIT: FastKAP will significantly reduce span times for F-35 fastener installation because most, if not all, of the preparation activities are moved offline and out of the critical path. Time-consuming activities of fastener gathering, cleaning, and application of adhesion promoter are taken out of the work cell and relocated to an offline central kitting area. Fastener kits are assembled using accurate forecasting information, including as-built grip length measurements. Installers are provided a complete kit of parts required for a specific detail or job, eliminating wasted time interpreting drawings, dealing with inaccurate grip lengths, searching for parts in PLS or free stock racks, and creating handmade labels. FastKAP automated systems perform the cleaning, promoting, bagging, and labeling processes, eliminating most of the touch labor involved in the process. Installers are always installing fasteners rather than doing non-value-added activities that can be done offline without impacting span time. SMRC enters the Phase I program with a good understanding of existing F-35 manufacturing challenges, an established transition partner, Electroimpact, and a clear commercialization roadmap, ensuring that FastKAP will make it to the market supported by a respected global leader.