Deep dive ⑥ · Realize

EBOM · MBOM · Quality

The as-designed structure becomes an as-planned build: a 22-item engineering BOM, a stage-based MBOM, a 10-operation process plan, and a process FMEA + control plan — carrying the reliability decisions all the way to the shop floor.

Tool: Teamcenter Active Workspace 22-item EBOM OP10–OP100 process PFMEA + control plan

Engineering BOM

The full 22-item structure, built in Active Workspace

The as-designed structure — QX250-100 — across five subsystems. The redundancy the reliability study demanded (2 batteries, 2 flight controllers, a BMS) is carried in the BOM, so the physical part list still equals the MADe model. Quantities are set on the structure (Arm ×4, Standoff ×8, Motor ×4, Prop ×2).

Teamcenter EBOM QX250-100 expanded structure, 20 of 22 items
EBOM — the expanded structure. QX250-100 → Airframe (202–205, 201), Propulsion (301–303), Power (401–404), Avionics (501–503), with quantities.Active Workspace · QX250-100 · Content (ACE)
Teamcenter EBOM wiring harness subsystem
EBOM — Wiring Harness Set. QX250-600 → the motor-lead harness (601) and signal harness (602), completing the 22-item tree.Active Workspace · QX250-100 · Content (ACE)
QX250-100 UAV Final Assembly ├ 200 Airframe (201 top plate, 202 bottom plate, 203 arm ×4, 204 standoff ×8, 205 HW kit) ├ 300 Propulsion (301 motor ×4, 302 prop CW ×2, 303 prop CCW ×2) ├ 400 Power (401 battery ×2, 402 ESC 4-in-1, 403 PDB/BMS, 404 XT60 lead) ├ 500 Avionics (501 flight controller ×2, 502 ELRS RX, 503 VTX + cam) └ 600 Wiring (601 motor-lead harness ×4, 602 signal harness)

Manufacturing BOM

Re-cast by build stage

The engineering structure is re-cast into an as-planned MBOM — QX250-M100 — organised by build stage rather than by system, each tied to an operation.

Teamcenter MBOM QX250-M100 build-stage structure
MBOM — by build stage. QX250-M100 → Propeller Install [OP70], Airframe Sub-Assembly [OP20], Electronics Stack Sub-Assembly [OP30].Active Workspace · QX250-M100 · Content (ACE)

Process plan & quality

Ten operations, with quality controls that carry the reliability findings

An Easy Plan process of ten operations (OP10–OP100) with full work instructions, plus a process FMEA and control plan that govern the build. Note how the reliability findings persist: the order-1 loss-of-thrust cut set (REL-003) is the top-severity process item, and the redundant FC (REL-009) mitigates the FC-handling failure mode.

Teamcenter Easy Plan process element 038807 with OP10-OP100 instructions
Teamcenter Easy Plan — the process element. 038807 "QX-250 Assembly Process Plan (OP10–OP100)", an MEProcessElement that consumes the MBOM, with the operation-by-operation work instructions.Active Workspace · 038807 · Overview

Assembly process — OP10 to OP100

OpOperationKey work instruction
OP10Kit & stage partsVerify count vs MBOM; ESD wrist strap on
OP20Assemble airframeArm screws 0.6 N·m + Loctite 243
OP30Build electronics stackESD-critical; solder ESC pads; stack dual FC on standoffs
OP40Install motors & route leadsMotor screws 0.5 N·m; route leads along arm
OP50Solder motor leads to ESCPhase order per motor position; heat-shrink each joint
OP60Battery tray & BMS wiringVerify XT60 polarity; strain-relief leads
OP70Mount propellersCW on arms 1&3, CCW on arms 2&4 (Quad-X)
OP80Bind RX, flash/config FCELRS bind; set motor dir; failsafe = motors off
OP90Bench testT:W ≥ 2:1, AUW ≤ 700 g, failsafe cut, no vibration
OP100Final inspection & packQA sign-off; record serial; pack

Process FMEA — highest-risk modes

OpFailure modeEffectSevRPNAction
OP50 solderCold / insufficient jointIntermittent phase → motor cutout in flight9108Iron 350 °C SOP; 100% joint inspection
OP20 airframeArm screw under-torquedArm loosens → vibration / crash784Calibrated torque driver; Loctite 243
OP40 motor mountScrew too long into motorWinding short → loss of thrust (REL-003)981Kit correct screws; poka-yoke length gauge
OP30 stackFC not seated / ESD damageFC failure (mitigated by REL-009 redundant FC)672ESD mat + strap; functional self-test
Honest scope. The 22-item EBOM, the top MBOM stages and a live inspection definition are real in the Teamcenter instance. The full MBOM stage set, the Easy-Plan operation nodes and the complete PFMEA / control plan are authored as load-ready specifications and partially keyed in — the Active Workspace BOM editor grew unstable under automation late in the session (logged in the Tool Scorecard), so the remainder was delivered as spec rather than risk corrupting live data.