Automation in Aerospace & Defense (A&D) Manufacturing

Role of cost effective automation as a business strategy to compete in the

global marketplace

Curtis A. RichardsonAssociate Technical Fellow - Automation

Spirit AeroSystems, Inc.

Why Automate?

Nonrecurring Cost

Capa

bilit

y

Traditional 2D Perspective

• Increase/stabilize productivity or throughput• Reduce/avoid/stabilize cost• Improve/stabilize quality• Improve safety, ergonomics• Regulatory compliance• Technology or capability

enablerHand Tools

FlexibleAutomation

Monument Automation

Why Flexible Automation?

• Installation, process integration flexibility• Cost-effective capacity scalability• Minimal lead times

Capa

bilit

y

Nonrecurring Cost Flexibility

Total 3D Perspective

What’s so great about robots?

• Relatively low capital cost• Relatively low installation cost/requirements• Process flexibility• High degree of repeatability• Offline TCP programming capability• Range of motion, speed, payload• Large network of integration specialists• Mass produced• Mature infrastructure

Low volume, high mix Large parts Multi-task oriented Cycle time (per part) measured in

hours/days Mobile cell / flexible fixturing High accuracy required Application-dependent speed End effector function integral to

the process No model run changeover Multi-model/part families Offline programming Cognitive interpretation

High volume, low mix Small parts Single-task oriented Cycle time (per part) measured in

seconds/minutes Static cell / tooling configuration Low/no accuracy requirement Maximize robot motion speed Robot motion integral to the

process Annual model run changeover Single model/part family focus Teach programming “Set it & Forget it”

*Traditional vs. A & D Use

vers

us

* “Traditional” markets include automotive, electronics, etc.

Traditional Industry Use Characteristics Typical A & D Use Characteristics

Precision Drilling Fastening/Riveting Non-Destructive Inspection Sealing: fay, fillet, encapsulation Coating: paint, plasma spray Sanding Fiber/Fabric Placement Assembly & Fixturing Peening Friction Stir Joining Precision Routing Machining/Sculpting

Welding: arc, spot, laser Assembly Cutting Grinding/Deburring Dispensing Machine Tending Trimming: routing, waterjet Packaging Palletizing Painting Polishing/Finishing Press/Forming

vers

us

* “Traditional” markets include automotive, electronics, etc.

Processes

Accura

cy-c

ritical

,

high-fo

rce,

inte

ract

ive

proce

sses

*Traditional vs. A & D Use

However, there are some issues…

• Robotic automation not designed for most accuracy-critical, high-force, interactive applications– Accuracy, stiffness, cognitive capability requires fundamental design changes– Perceived as relatively low-volume opportunity by OEMs– Deficiencies addressed at system integrator level (customization);

unexpectedly high turnkey system cost– Diverse landscape of integrators can be confusing

• 2nd tier measures to improve performance result in cost, reliability issues

• Myriad safety, process integration inefficiencies• Complexity, idiosyncrasies of proprietary controllers• Fear of losing jobs to automation

How do we address these issues?

1. Use what’s already working… Implement automation where current technology allows Gain familiarity, expertise

2. Establish internal automation infrastructure Skilled trades for programming, operating, maintaining Develop guidelines, standards for automation utilization Implement control, data network architectures

3. Adapt engineering designs, manufacturing processes Design for Automated Manufacturing (DFAM) crucial Greenfield scenarios vs. existing process improvements

How do we address these issues?

4. Collaborate with each other SME Aerospace Automation Consortium SAE Aerospace Manufacturing & Automated Fastening Midwest Robotics Initiatives Council NSF Roadmap for US Robotics

5. Partner with OEMs, integrators, researchers Educating OEMs about process requirements, market

potential will lead to new capabilities, designs Some progressive integrators already addressing issues Research institutions provide opportunities for shared

resources, short-term results Use collaborative environment to garner government

resources