Accialini Training & Consulting provides support in Gear Manufacturing. Please visit our website www.accialiniconsulting.com or send us an email at info@accialiniconsulting.com for additional info. Please don't forget to subscribe to our newsletter!

1. Accialini Training & Consulting
Senior Consultant
Gear Manufacturing
Support
Nicola Accialini

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About
• Mechanical transmissions are considered a tough topic to
face with. Indeed, they required high skilled professionals at
each stage of their development, from concept generation to
manufacturing.
• Focusing on manufacturing, traditionally gears require
special dedicated machines, fixture and tools to machine
gear’s teeth, a wide range of industrial steps, including (but
not limited to) special processes and non-destructive tests.
• Moreover, in the last years more demanding standards are
required to fulfill new requirements for more challenging
applications.

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The Objectives
• Mitigate risks during the industrialization of
new mechanical transmissions
• Implement new standards
• Reduce production costs
• Reduce the time to market
• Improve process robustness to develop more
reliable products

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The Opportunity
• Implement a structured ad at the same time
flexible methodology to develop new
mechanical transmissions;
• Implement a collaborative and high-
performance culture throughout the
organization;
• Foster new technology trends to support the
overall approach.

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The Solution
• Perform a structured Concurrent
Engineering approach
• Define a proper Method of
Manufacturing
• Perform a PFMEA to mitigate risks
• Define proper tools and fixtures

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Our Proposal
• Due to their great use in all engineering fields, the gear business
is continuously growing, new design techniques, new
requirements and new standards have been set up and are
continuously improving every year.
• A good Method of Manufacturing must take into account several
aspects, among which, but not limited to:
• Use adequate machines;
• Implement a proper sequence;
• Use the right tools and fixtures;
• Use the right inspection methods;
• Specify the right tolerances at each stage

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Why ATC
• ATC has collected 10+ years of experience in developing high-
quality critical modules in the aerospace industry, more
specifically accessory and power gearboxes for aeroengines,
probably the most critical parts of an airplane.

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The Approach
• Our execution strategy incorporates proven
methodologies, extremely qualified personnel, and a
highly responsive approach to managing deliverables.
• Our execution strategy aims primarily to provide the
organization the proper support in the industrialization of
new mechanical transmissions. The details of the
approach will be described in the following section.

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Requirements definition
• The first step consists to understand
• Financial Requirements (e.g. final costs)
• Technical Requirements (e.g. specifications,
dimensions, tolerances)
• Project Requirements (e.g. time schedule, resources)
• With these basic informations, a preliminary
industrialization plan can be defined.

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Preliminary Industrialization Plan
• The first step is to develop a preliminary industrialization
plan, which includes:
• Number and skills of people involved in the project;
• Estimated Budget;
• Time schedule;
• Potential bottlenecks

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Concurrent Engineering
• Concurrent Engineering is probably the most important stage,
because here most of the issue can be solved in advance.
Concurrent Engineering implies the collaboration of Design and
Manufacturing Department to design the component
concurrently. This means that all features, requirements and
tolerances are defined together, taking under consideration either
design and manufacturing needs.
• In real life, to shorten the time to market, it is necessary to start
the manufacturing process before the design is finalized. For this
reason, some preliminary features must be agreed and frozen in
advance to allow the purchasing of Long Lead Time items.
• This stage can be performed on-site or even remotely, or a
combination of both. The recommendation is to start with online
discussion, then finalize the drawing with a face to face meeting.

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Definition of the Method of Manufacturing
• The core activity implies the definition of the overall Method
of Manufacturing, from row material to final inspection.
• This stage implies different steps, including the definition of:
• the manufacturing sequence;
• machines and plants;
• geometric shape and tolerances at every step;
• work instructions;
• in-process inspection plan;
• the right specification to use;
• tools and fixtures, including inspection tools;
• stack up analysis, to guarantee that the final
requirements can be fulfilled

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PFMEA generation
• A Process Failure Mode Effects Analysis (PFMEA) is a
structured analytical tool used by an organization, business
unit, or cross-functional team to identify and evaluate the
potential failures of a process. This document it is normally
required by suppliers especially when a PPAP approach is
applied. However, PFMEA is a very powerful tool to prevent
criticalities within a manufacturing process.
• PFMEA are normally generated in parallel with the method
of manufacturing and it typically implies an iterative
approach: when a potential issue is discovered and a
solution identified, then the MoM is modified and so on.

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Definition of Tools & Fixtures
• The definition of Tools & Fixtures can be considered a
"process inside the process". ATC has gained several years
of experience in the design and implementation of tools &
fixtures in the gear manufacturing business. Therefore, ATC
is capable to support the T&F team to identify the most
appropriate solution. It is worth to highlight that ATC doesn’t
provide a fully detailed design of Tools & Fixture, but a
sketch of concepts with main requirements.
• Moreover, ATC provides support in the creation of a so
called “Tools & Fixtures Passport”, which document all
features of the component and keep track of all changes.
This is very important to guarantee the high standard of the
process.

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Benefits
• Financial
• Reduce the iterations associated with gears
industrialization
• Reduce internal costs associated with gears
industrialization
• Technical
• High quality Method of Manufacturing guaranteed

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• If you are interested, please submit these few information
and help us to tailor the service to fit best to your needs:
• Work package: How would you prefer to run the project?
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nicola@accialiniconsulting.com
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