Leakage problem and solution suggestions in aviation lighting systems

Today, the use of aircraft is increasing rapidly. With the developing technology, the durability of the parts and equipment used in aircraft which is one of the most reliable transportation vehicles is important. Lighting systems are one of these parts used in aircraft. In this study, in the first stage, the problems encountered in the lighting system assembly line in a factory were subjected to project-based diffraction and 5 different problems were determined. These problems were identified as leakage, lens surface scratch, missing injection, lack of socket and housing broken. When the lighting system assembly line defects were examined, it was determined that the most common error was the leakage defect due to geometry. The raw material, production parameters and production method of the upper package/middle package part of the produced lighting system were examined and it was observed that the hot welding apparatus could not be welded due to time-dependent wear and the geometry shifted from the axis or it gave a leakage defect. With the work improvements, the problem was solved by limiting the setting depending on the standard part on the hot welding machine by changing the middle part defect rate from 1.45% to 0.95% with injection machine interventions.