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Automation in Aerospace & Defense (A&D) Manufacturing

Automation in Aerospace & Defense (A&D) Manufacturing. Role of cost effective automation as a business strategy to compete in the global marketplace. Curtis A. Richardson Associate Technical Fellow - Automation Spirit AeroSystems, Inc. Why Automate?.

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Automation in Aerospace & Defense (A&D) Manufacturing

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  1. Automation in Aerospace & Defense (A&D) Manufacturing Role of cost effective automation as a business strategy to compete in the global marketplace Curtis A. Richardson Associate Technical Fellow - Automation Spirit AeroSystems, Inc.

  2. Why Automate? • Increase/stabilize productivity or throughput • Reduce/avoid/stabilize cost • Improve/stabilize quality • Improve safety, ergonomics • Regulatory compliance • Technology or capability • enabler Traditional 2D Perspective Monument Automation Capability Flexible Automation Hand Tools Nonrecurring Cost

  3. Why Flexible Automation? • Installation, process integration flexibility • Cost-effective capacity scalability • Minimal lead times Total 3D Perspective Capability Flexibility Nonrecurring Cost

  4. 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

  5. *Traditional vs. A & D Use Traditional Industry Use Characteristics Typical A & D Use Characteristics • 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” • 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 versus * “Traditional” markets include automotive, electronics, etc.

  6. *Traditional vs. A & D Use Processes • Welding: arc, spot, laser • Assembly • Cutting • Grinding/Deburring • Dispensing • Machine Tending • Trimming: routing, waterjet • Packaging • Palletizing • Painting • Polishing/Finishing • Press/Forming • 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 Accuracy-critical, high-force, interactive processes versus * “Traditional” markets include automotive, electronics, etc.

  7. 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

  8. How do we address these issues? • Use what’s already working… • Implement automation where current technology allows • Gain familiarity, expertise • Establish internal automation infrastructure • Skilled trades for programming, operating, maintaining • Develop guidelines, standards for automation utilization • Implement control, data network architectures • Adapt engineering designs, manufacturing processes • Design for Automated Manufacturing (DFAM) crucial • Greenfield scenarios vs. existing process improvements

  9. How do we address these issues? • Collaborate with each other • SME Aerospace Automation Consortium • SAE Aerospace Manufacturing & Automated Fastening • Midwest Robotics Initiatives Council • NSF Roadmap for US Robotics • 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

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