Designing a 3D Printing Lab at Collins Aerospace

Abstract

Collins Aerospace, a global leader in aerospace and defense manufacturing, has recognized a need to optimize its 3D printing services at its Santa Isabel facilities (PR-4 and PR-7). Since 2022, a designated area for 3D printers has been identified as a requirement to address inefficiencies and reduce reliance on external suppliers, which currently inflate production costs by 75%. This project aims to enhance 3D printer utilization by creating an optimized laboratory layout and addressing training, accessibility, and maintenance gaps. In the define phase, a Voice of the Customer (VOC) survey revealed insufficient user training, limited material accessibility, and a lack of preventive maintenance as critical issues. Internal customers reported full equipment utilization but faced availability challenges, while external customers were largely satisfied with delivery and quality but unaware of the service request process. A SIPOC diagram was developed to map the 3D printing process, identifying suppliers, inputs, and outputs, alongside a stakeholder matrix to pinpoint key project participants. The measure phase validated the measurement system and explored root causes through data collection from February to March 2023 and historical reports from August to October 2022. Findings highlighted shifts in demand: PR-4 experienced a decline from 61% to 13%, while PR-7 saw an increase from 39% to 87%, potentially linked to personnel changes. Utilization rates varied across printers and buildings, with material preferences also differing. These insights inform strategies to improve availability, training, and inventory monitoring, aligning with customer needs and boosting operational efficiency.