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An aircraft’s detail part and assembly product design and development phase contribute to about three-fourths of the total cost spent in its entire product life cycle and determine the fate of the aircraft’s life as a whole. Each aerospace design organization presently has developed their own set of design rules, focusing on improving product design capability by enhancing the determined “Design for X” factor, with the focus on continual optimization and improvements. However there is huge variation among these design principles due to the nonstandardization of these design guidelines. To meet this gap, the use of Design for Manufacturing and Assembly (DFMA®) principles applicable for aerospace has to be developed. DFMA®) principles have been proven effective as guidelines to designers and manufacturing engineers in various discrete manufacturing and process industries.

The selection of aircraft consumable materials in aerospace manufacturing and assembly processes is a major customer design data-driven process, which is designed and developed early at the product design stages. With the rapid improvements in the aerospace manufacturing and assembly industry, these consumable material sources are prone to both obsolescence and counterfeit risks. Thus, aircraft design teams must carefully identify the selection of these materials and sources, which can provide products and services till the end of the product life cycle, which, if not, can impact both the design and the functional intent of the aircraft assembly. The study discusses the challenges faced in the current aerospace consumable industry and the opportunities for improvement in it.

In Today’s World, Every Manufacturing and Service Industry aims in providing the Highest Quality of Products and Service at the lowest Competitive Cost and timely delivery to its Customers. The Discrete Aerospace Manufacturing and Assembly industry is taking initiatives to implement the Process Failure Modes and Effects Analysis (PFMEA) tool for its critical Aerospace Manufacturing and Assembly suppliers, by implementing Aerospace Standards, in an effort to create a synergy between the End user customers, Original Equipment manufacturers and the suppliers, for ensuring increased safety, quality, reliability for the Aircraft parts and components produced by them. The main aim is to use this concept as a Process Risk Management tool for Identification, Assessment, Mitigation, Control and Prevention of risks associated with Designs and Manufacturing.