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delivered prior to, or simultaneously with, F-16's identified for
earlier program years. There was no fixed model or type of F-16,
and GENDYN did not maintain an inventory of unsold aircraft. The
F-16 aircraft were to be constructed on an ongoing basis pursuant
to the specifications required by the contract and set by the Air
Force.
The manufacture of F-16's under multiyear contracting was a
complex process. From the procurement of long-lead items through
final assembly and testing, it took GENDYN 2-1/2 to 3 years to
build the first aircraft. Fabrication and assembly took
approximately 13 months. At least 1 year before the first
aircraft could be built, GENDYN had to establish the production
configuration from which it would develop the drawings and bills
of materials. The plant then had to develop and test the
production tools and otherwise complete production planning.
GENDYN would then issue purchase orders for the major subsystems
and components, including radars, computers, screens, and
sensors. GENDYN would then purchase the raw materials (e.g.,
aluminum) necessary to fabricate the different parts of the
aircraft.
The aircraft were fabricated using a modular approach on a
production line nearly 1 mile long. Pieces of the airframe,
including the forward fuselage, inlet, center fuselage, aft
fuselage, stabilizing tail assembly, and wings, were designed and
fabricated separately and then joined together on the line. Some
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