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Aerospace assembly models are exceptionally large and complex. Bombardier’s dimensional management team works with five or more levels of sub-assemblies and thousands of individual parts, making it difficult to know where to even start a tolerance study.
Design changes occur constantly during development, forcing models to be updated continuously — while getting reliable statistical data from suppliers is often next to impossible.
To meet these challenges, Bombardier’s team follows an established process: identify the requirements, identify the assembly process, analyze and optimize through iteration loops, then flow the validated requirements down to suppliers. Once supplier data comes back, the 3DCS model is updated with bottom-up feedback — incorporating real part capabilities, tooling constraints, and assembly process data — to produce a stack analysis that flags the risk of missing Bombardier’s dimensional requirements before parts reach the shop floor.
Bombardier’s team builds its dimensional models directly in 3DCS Variation Analyst, applying tolerance analysis and variation management principles to prioritize DCS measurement points over full feature-based geometry, keeping offline mockups lightweight and stable over time. One model is built per assembly level, letting the team run early worst-case analyses and apply a security factor when supplier mean-shift data isn’t yet available.
Iteration loops built around the 3DCS model let Bombardier react quickly to supplier feedback on tolerance conflicts, keeping assembly programs on schedule.
Reduced cost at the final assembly line (FAL) and aircraft reaching maturity from the very first production unit.
Every requested tolerance is backed by fact-based, model-driven discussion with suppliers, removing over-engineered requirements.
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