De‑risk your ramp. CUG’s LRIP programs take proven prototypes and first articles into controlled, repeatable, and cost‑aware production—without jeopardizing quality, schedule, or certification.
Snippet‑ready summary: Low‑Rate Initial Production (LRIP) in composites is a controlled phase between prototype/qualification and full‑rate manufacturing that validates tooling, processes, supply chain, and documentation at limited volumes (e.g., pilot lots) to prove repeatability, cost, and schedule. CUG runs LRIP with FAI/FAIR compliance, SPC on key characteristics, and a gated plan from DFM to rate‑readiness.
What LRIP Means in Composites
LRIP is the bridge from engineering development to steady‑state production. For composite structures, it confirms that laminates, bonding, cure cycles, machining, and NDI deliver the same results part after part, while aligning material flow, staffing, work instructions, and quality documentation.
LRIP objectives:
- Validate tooling (thermal stability, spring‑in/spring‑back control, repeatable datum scheme)
- Lock special processes (autoclave/OOA cure, infusion/RTM parameters, adhesive bonding)
- Demonstrate dimensional capability with SPC on critical features
- Prove yield & takt (cycle times, changeover, and rework rates)
- Qualify suppliers and materials with lead‑time and lot‑to‑lot stability
- Deliver audit‑ready documentation (AS9102 FAIRs, travelers, cure logs, NDI evidence)
CUG’s LRIP Framework (Gated)
Gate 0 — NPI Handoff
- Requirements, CAD, drawing pack, acceptance criteria, CTQs/CCs identified
- Preliminary process flow (PFMEA outline) and risk register
Gate 1 — DFM & Process Selection
- Laminate & stack‑up finalization; bond/joint strategy
- Process choice (prepreg autoclave/OOA vs infusion/RTM); preliminary cure recipes
- Tooling concept, datum plan, trimming/drilling strategy
Gate 2 — Tooling & Work Instructions
- Soft/hard tools released; datum features and cure fixtures validated
- Travelers/ply books, WI, inspection plans, and NDI plans drafted
- Metrology plan defined (CMM/laser), gage R&R scheduled
Gate 3 — First Articles (FAI/FAIR)
- Forms 1–3 completed with ballooned drawing/model
- Material certs, cure charts, and NDI evidence captured
- PPAP‑style control plan (if requested) baselined
Gate 4 — Pilot Lot (LRIP Run)
- 10–30 piece pilot (typical) with SPC on CTQs; Cp/Cpk reported
- Yield, cycle time, and staffing model validated; rework Pareto and corrective actions
- Supplier performance checks (OTD, lot stability, attrition)
Gate 5 — Rate Readiness
- Finalized control plan and capacity model; EPEI/kanban sizing
- Change‑control/counterfeit‑parts & shelf‑life controls verified
- Handoff to full‑rate with costed BOM/routings
LRIP Deliverables
- AS9102 FAIR package (Forms 1–3 + ballooned drawing/model)
- Control plan & PFMEA (or equivalent risk summary)
- SPC pack: characteristic list, sampling plan, capability (Cp/Cpk), trend charts
- Process evidence: cure cycle records, tool IDs, debulk steps, bondline controls
- NDI records: UT C‑scan maps or agreed visual criteria; dispositions
- Dimensional reports: CMM results tied to datum scheme
- Quality dashboard: yield, scrap, rework Pareto, and corrective actions
Process Controls We Validate in LRIP
- Layup discipline: ply orientation, drops, lap lengths; barcode/ply‑kit tracking
- Thermal controls: thermocouple placement, ramp/soak/pressure verification, vacuum integrity
- Bonding: surface prep, adhesive film cure, potting/inserts, torque logs
- CNC trim/drill: program revision control, fixture repeatability, hole quality
- Finishing: paint/clear‑coat callouts, Class‑A cosmetic acceptance (weave telegraphy, pinholes)
Sample LRIP Timeline (Illustrative)
| Phase | Duration | Output |
|---|---|---|
| Tooling Release & Tryout | 3–6 weeks | Tools validated, datum plan confirmed |
| First Articles (FAI) | 2–4 weeks | FAIR approved, baseline capability |
| Pilot Lot (10–30 pcs) | 3–5 weeks | Cp/Cpk ≥ 1.33 on CTQs, yield ≥ 95% |
| Rate Readiness | 1–2 weeks | Control plan locked, staffing & takt modeled |
Actual timing depends on part size, complexity, and material lead times.
Supply Chain & Material Readiness
- Prepreg/core/adhesive forecasts with safety stock & shelf‑life management
- Approved second sources where possible; incoming inspection plans
- Freezer capacity and FIFO procedures; lot traceability through travelers
Digital Thread & Configuration Control
- Rev‑controlled CAD/CAM, tool models, and WIs
- ECN/ECR workflow with impact analysis (delta FAI triggers)
- Serialized builds with traveler history retained for audits
Metrics We Report Every Run
- Yield / Scrap % and primary defect modes
- Cycle time vs. takt; capacity utilization
- Dimension capability (Cp/Cpk) for CTQs
- OTD and supplier lot conformance
Why Run LRIP with CUG
- Aerospace‑grade discipline with practical cost control
- End‑to‑end ownership from DFM and tooling to NDI and bonded assemblies
- Transparent dashboards so your team can move to rate with confidence
FAQs
How many parts qualify as LRIP?
Enough to demonstrate capability and stabilize yield—often 10–30 per part number, but we match customer requirements.
Is an FAI always part of LRIP?
Yes, for new part numbers or major changes. Delta FAIs are used when only certain characteristics or processes change.
What capability index is acceptable?
Most aerospace programs target Cp/Cpk ≥ 1.33 for critical features; we align to your control plan.
Do you handle bonded assemblies?
Yes—co‑bond/secondary bond structures, insert/potting details, torque logs, and adhesive cure evidence are standard.
Get Started
Send your drawings/models, expected volumes, rate targets, and acceptance criteria. We’ll return a LRIP plan with schedule, risk mitigation, and pricing option
