Constellation Satellite Manufacturing

Constellation manufacturers are innovating ways to build satellites in much higher production quantities. In this post, we go on a “virtual” plant tour and benchmarking visit to a commercial constellation manufacturer to observe how a company views high-volume production, applies lean concepts (eliminating waste throughout manufacturing), and sets up assembly lines for satellites in the space industry.?

A Plant Tour, Anyone?

Because of the high volumes involved, commercial constellation manufacturers view their satellite production system as something equivalent to Henry Ford’s assembly line for automobiles. They have effectively used manufacturing technologies from automotive and aircraft industries to support a “line-balanced,” synchronized system. To support this synchronized approach companies use several key innovative approaches.

For example, they use automated guided vehicles (AGVs) to transport the satellite from location to location. With the push of a button, they send the satellite to the next step in the process. Wireless electronic torque tools are used to capture torque data in a database and notify a technician if a process is out of statistical control. Optical inspection equipment is used to quickly inspect a completed assembly to determine if any parts are missing or if a part is in an improper orientation (e.g., installed backwards).

To support a synchronized assembly line, manufacturers may need to change the design of the satellite. To design each satellite with reproducibility in mind, they design using a “flat bill of materials,” with only three levels of assembly in some cases (e.g., satellite, module/subsystem, component/unit). A flat bill of material is just one design approach needed for the quick and responsive manufacture of constellation satellites.

Production-line satellites are also designed for ease of manufacturing, i.e., the design teams consciously minimize the number of parts used, reduce the number of different part types, and standardize common parts wherever possible. For example, a design team might specify all No. 10 screws throughout the design to reduce the part numbers carried in inventory and to help error-proof the design by eliminating the possibility of using the wrong screw size.

All of these innovations support high production rates of constellation satellites similar to what happens in the automotive or aircraft industries. Today’s commercial and government satellite assembly lines provide a window into constellation satellite manufacturing and a glimpse into the future for how we will build satellites in much higher production quantities.

?

Jeff B. Juranek is currently a Project Leader Sr., Engagements, in the Corporate Chief Engineer’s Office at The Aerospace Corporation. Prior to that Juranek worked as a Department Manager in Systems Engineering and Space Reliability at Raytheon Space & Airborne Systems and at Boeing Satellite Systems (formerly Hughes) as both a production manager and IPTL for XIPS power supplies, on product effectiveness, and worked with parent GM/Delco Electronics to assist in bringing the lean philosophy to satellite manufacturing. Juranek holds a B.S in Industrial Technology from Iowa State University, and an M.S. in Quality Assurance for California State University Dominguez Hills. In addition, he holds a Certificate in Production & Inventory Control; a Certificate in Manufacturing Engineering, Electronics; and is a certified quality engineer through the American Society for Quality.

Getting It Right focuses on industry collaboration for mission success by sharing lessons learned, best practices, and engineering advances in response to the nation’s toughest challenges. It is published by the Aerospace Corporate Chief Engineer’s Office. ?