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?
Increase/stabilize productivity or throughput
Reduce/avoid/stabilize cost
Improve/stabilize quality
Improve safety, ergonomics
Regulatory compliance
Technology or capability
enabler
Traditional 2D Perspective
Capability
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Monument
Automation
Flexible
Automation
Hand Tools
Nonrecurring Cost
Why Flexible Automation?
• Installation, process integration flexibility
• Cost-effective capacity scalability
• Minimal lead times
What’s so great about robots?
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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
*Traditional vs. A & D Use
Traditional Industry Use Characteristics
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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”
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versus
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Typical A & D Use Characteristics
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* “Traditional” markets include automotive, electronics, etc.
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
*Traditional vs. A & D Use
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Welding: arc, spot, laser
Assembly
Cutting
Grinding/Deburring
Dispensing
Machine Tending
Trimming: routing, waterjet
Packaging
Palletizing
Painting
Polishing/Finishing
Press/Forming
versus
Processes
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* “Traditional” markets include automotive, electronics, etc.
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
However, there are some issues…
• Robotic automation not designed for most accuracycritical, 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…
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Implement automation where current technology allows
Gain familiarity, expertise
2. Establish internal automation infrastructure
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Skilled trades for programming, operating, maintaining
Develop guidelines, standards for automation utilization
Implement control, data network architectures
3. Adapt engineering designs, manufacturing
processes
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Design for Automated Manufacturing (DFAM) crucial
Greenfield scenarios vs. existing process improvements
How do we address these issues?
4. Collaborate with each other
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SME Aerospace Automation Consortium
SAE Aerospace Manufacturing & Automated Fastening
Midwest Robotics Initiatives Council
NSF Roadmap for US Robotics
5. Partner with OEMs, integrators, researchers
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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