New Rolls-Royce Facility Helps Power Military Fighter
Rolls-Royce leaders describe it as as one of the most advanced "aircraft out there," and the high-tech work providing some of the support for the F-35 Lightning II military fighter is taking place at a new manufacturing facility in Plainfield. Rolls-Royce refers to the new Hendricks County facility as the "Focused Factory," because it was built from the ground up to be the company's most high-tech, lean manufacturing operation yet with one laser-sharp focus: to build incredible technology in a competitive environment.
The main purpose of the $12 million factory, the company's 11th Indiana facility, is to manufacture two key components for the F-35, also known as the "Joint Strike Fighter." The supersonic, radar-evading fighter will be used by the U.S. and United Kingdom military.One of the key features of the Joint Strike Fighter is its short takeoff and vertical landing (STOVL) capability, and Rolls-Royce is manufacturing the technology to make it possible. Rolls-Royce's LiftFan and VaneBox technology being built at the new facility allows the aircraft to take off in extremely short distances, convert from supersonic speeds to hover mode and land vertically—no runway needed. Watch video of the Joint Strike Fighter
"It's definitely a unique system in this aircraft that doesn't exist in any other aircraft," says John Gallo, executive vice president of business operations at Rolls-Royce Corporation. "It gives the aircraft more options and more capabilities of where it can go. Sometimes infrastructure—airports and so forth—are limited in [military fighting conditions]. This aircraft can go places that other aircraft wouldn't be able to go." Listen
The LiftFan directs airflow downward, giving the aircraft power to execute short takeoffs and vertical landings. The capabilities of the system are nothing short of awe-inspiring; Rolls-Royce says the LiftFan generates more than 20,000 pounds of thrust—enough power to raise 10 elephants to the top of the Eiffel Tower in just six seconds. The VaneBox, also being manufactured at the new facility, is a component within the LiftFan.
While three versions of the aircraft are being manufactured, Rolls-Royce's STOVL technology will be utilized in the version created for the U.S. Marine Corps, U.K. Royal Air Force and Royal Navy.
The entire aircraft program is designed around affordability, made possible in part by streamlined assembly methods that cut production time. Rolls-Royce leaders say the Focused Factory was designed with competitiveness as a top priority, utilizing lean manufacturing methods to improve performance and cut costs.
"This facility and a lot of the technology in it is a first for Rolls-Royce in Indianapolis," says LiftFan Assembly Senior Manager Anthony Woodard. "It's new technology, it's new to the industry and it's new to the area. It's something very unique and very impressive from a technology and competitiveness perspective." Listen
Rolls-Royce leaders say the facility is its most advanced yet, pointing to a long list of state-of-the-art equipment and likening its overall cleanliness to an operating room. An Intelligent Tool Control System electronically tracks each tool in the 35,000 square foot facility, a dry ice part cleaning system removes impurities in an environmentally-friendly manner and air casters—rather than forklifts—are used to maneuver the 3,000 pound LiftFans throughout the facility.
"Everything we've done at this facility utilizes lean manufacturing—the leanest, latest and greatest, state-of-the-art assembly technologies," says Woodard. "Competitiveness is key. This facility ensures we can assemble these LiftFans and VaneBoxes with a competitive cost structure; that gives us the capability and potential to bid for new work and bring that into Rolls-Royce's portfolio here in Indianapolis." Listen
Rolls-Royce leaders say the Focused Factory was built in Plainfield primarily because of its close proximity to the company's LiftFan testing facility in Indianapolis, the only such facility in the world. Listen
"Everybody who has been part of this program is extraordinarily excited," says Woodard. "It's exciting from a technology standpoint, but also from the standpoint of leading competitiveness within Rolls-Royce."
Rolls-Royce leaders say the Focused Factory had its ribbon-cutting ceremony in June, marking the launch of an impressive facility doing even more impressive work—giving power to one of the world's most advanced aircrafts.