The aerospace industry has traditionally been conservative in its approach to automation, and has its own challenges to address. You may be surprised to learn that the aerospace industry – which is known for its complex and state-of-the-art systems – still relies heavily on manual labour. Aerospace manufacturers are currently dealing with huge backlogs and need a solution that speeds up production – and many companies are looking to automation to solve this problem! For example, the scale and size of aircraft is of course a unique factor that must be accommodated. Large part sizes often result in operators and robots working simultaneously on a given part; large parts may also mean robots need to be mobile in order to travel to the aircraft part instead of the part traveling to the robot. Additionally, relative to other industries, aerospace manufacturing is complex and low volume – meaning it has many different tasks in order to produce very few final products. Aircraft also use some materials, such as composites, that are unique to the aerospace industry. Automated drilling has been a mainstay of aerospace manufacturing for years – but now, systems and applications are becoming more diverse. Quality control, welding, coating, and more are increasingly falling under the purview of sophisticated automation systems. Although the aerospace industry has been responsible for staggering advances in engineering and basic science, new manufacturing methods struggle to catch on. The immense importance of safety, coupled with strict regulations, inspires a conservative approach. But aerospace is at a crossroads: Many major brands are struggling with enormous backlogs. To cope with this vast and growing challenge, industry leaders are taking a new tack. From more conventional automated drilling, companies have been pressed to embrace a range of automated surface preparation technologies. New technological developments are now addressing industry demands in a way that may create a "perfect storm" of innovation. It’s impossible to overstate how important automation has been in facilitating faster and more precise drilling – each aircraft has countless holes that must be flawless. In the near future, however, automation will become the solution to more sophisticated challenges:

· Throughput – executing outstanding orders faster and with less waste;

· Quality – delivering more effective components with easier maintenance;

· Ergonomics – ensuring all aspects of design respect the human factor;

· Safety – maintaining the industry’s tradition of overall safety excellence.

Due to unique requirements of the aerospace industry, relatively few OEMs and integrators are fully prepared to deliver “end to end” automation systems. Even the simplest task is complicated by the unique properties of the materials used in every aspect of aircraft.

Materials handling, the next frontier of aerospace automation, still faces many challenges. Collaborative robots that work closely with human counterparts are being embraced as one quality control solution. Ultimately, robotic systems are seen as the answer to repetitive, ergonomically challenging tasks – leaving highly trained aerospace experts free to oversee processes and perform the expert craftsmanship that defines industry excellence.

Benefits of Automation in Aerospace Industry -

· Automation increases efficiency - since automated processes can work 24/7 with occasional outages for maintenance – clearly faster than human operators can perform. Additionally, robots are able to work in tight spaces and can fit in hard to reach locations – further improving productivity.

· Automation improves safety - since operators no longer need to perform hazardous tasks such as picking up heavy objects, performing tasks with repetitive motion, or other potentially dangerous tasks.

· Automation improves quality control - by reducing the potential for human error and allowing early identification of potential issues, automation increases the reproducibility of production and helps ensure the final product does not vary.

· Automation protects the brand– which is crucial since aerospace companies rely heavily on their brand as it is often the key connection to the public and customers.

Advancements in Automation for Aerospace -

Automation can be used to increase safety, productivity, and the value of human effort. Tools with built-in guidance, providing user information and better manageability can provide a competitive advantage in terms of cost savings, while at the same time providing a better working environment. In some cases, hazardous steps can be fully automated to reduce workplace accidents and maintain production deadlines. In these cases, automation provides a control system or computer connected to a program that tells it to perform a series of tasks, with little or no human intervention required. Automation is currently being used in the aerospace industry to support worker productivity and reduce the need to perform repetitive tasks such as drilling and backfilling. However, there remains a significant need for increased automation as demand for new aircraft continues to outpace manufacturing supply. Industrial automation technologies have advanced significantly in recent years and are transforming the way manufacturers operate. Many concepts have evolved that describe this digitalization of manufacturing These concepts are now actively being deployed within the aerospace industry, allowing manufacturers to reap the benefits of these technologies now as well as position themselves to remain competitive in the future. Automation in the aerospace industry has been achieved to some extent, but not enough to make a dent on the gap between supply and demand. Even the automotive industry is farther along on the road to full automation compared to the aerospace industry, when, in fact, aerospace is widely considered as the front-liner in terms of innovation and technology

Designers, smart engineers and manufacturers have, and will continue, to push the envelope on load capacities for robotic equipment and end effectors in order to effectively handle the largest aircraft components.

While these may seem like daunting challenges to overcome, recent advancements in automation for aerospace technology address all of these, enabling automation to be an even more feasible and practical solution for aircraft manufacturing! The aerospace industry is ripe with automation possibilities and is expected to play an increasingly larger role in aircraft manufacturing as manufacturers are pushed to lower costs while maintaining quality in order to remain competitive.

Automation in the Aerospace Industry

Neelam Raysoni

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Automation in the Aerospace Industry

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