Please enable JavaScript.
Coggle requires JavaScript to display documents.
Industry 4.0 in Aircraft Manufacturing and Maintenance: Opportunities and…
Industry 4.0 in Aircraft Manufacturing and Maintenance: Opportunities and Challenges
Background
brief intro on IR
IR 1.0
IR 2.0
IR 3.0
IR 4.0
process of change from agrarian and handicraft economy to one dominated by industry and machine manufacturing
Current Scenario/Practices
IoT
example application
Airbus
use a tablet or smart glasses to scan an airplane's metal skin to determine what bolt size needed in a hole and the rotation force necessary to install it.
information can be sent to robotic tool spontaneously to complete the task
opportunities
provide contextual information to human worker - increased labour efficiency
connecting worker and their tool via ioT platform - manufcaturing accelerates as critical information flows seamlessly across the assembly line
tools being connected to accelerate the process - more reliable than manual tightening of bolt
handling assembly of up to 400000 bolts and screws using 1100 different tools
location tracking - identify location of tool in the factory and keep track of operator usage data and behavious
increase operator safety - only authorized and trained employee can use specific equipment
preventive maintenance - reduce aircraft downtime and increase safety of industry
sensor - monitor real time critical pefroamance
help ground staff to detect issue and quickly take corrective action
challenges
new skills and organization required
develop qualification of employees in software and data science
need to make sure every actor in the supply chain are integrated in the process to take full advantage of the transformation
time and cost of investing
cyber security
high aversion to risk and a global attitude of caution in regard to ICT technologies in the industry
high deployment time
introduction
what?
computing technology embedded in device
communicate through internet
advantages
communication within supply chain, eg sensor and actuator
streamlined, agile operation
greater visibility, transparency and connectivity
additive manufacturing
Introduction
what?
building object from 3D model
layer by layer
advantages
produce small number of complex, customized product
save cost- no need build specific manufacturing tool
time saving
can be done on demand
different materials : plastics, aluminium, titanium , glass etc
Application
Boeing state that at least 30 additively manufactured parts are embedded in the B&87 commercial aircraft
Am part are used for air ducts (B787, Bell 429 helicopter)
interiors/brackets eg A350
however only 1% of total parts in a commercial aircraft
Opportunities
reduce the spare parts warehouse for non-structural parts
produce spare part identical to those to be replaced
can be exploited to develop optimised spare part to be used during maintenance operations - optimised cad model (weight etc)
Challenges
Am parts need extensive studies related to consistency when used for structural application - strength and reliability issue
AR/VR
example application
MiRA (Mixed Reality Application) - airbus
use AR to scan parts and detects error on structures
time reduction of 80% for inspections of brackets in the fuselage
opportunities
AR and VR facilitate due diligence services at plants for installation of sensors and wireless networks, enabling condition monitoring of machines and shop floor integration
simplify intricate assembly line tasks, leading to flawless execution and reduction in turnaround time
It is also possible to create a digital twin of a physical object, such as an entire aircraft or its parts, and then carry out an in-depth analysis
AR can be useful to obtain Aug. Maintenance manuals and Illustrated Parts Catalogues where the position of the part to maintain is suggested to the operator in an intuitive way on the real aircraft
ARassembly/disassembly task presented to operator (CAD symboletc) to suggest manual operation to carry out
example: virtual screw driver, virtual panel where to check operation and interact with gesture tracking technologies
useful when dealing with complex operation which cannot be clearly explained with traditional paper manuals
challenges
time consuming to prepare animations
training
introduction
smart factory can virtualize assets and even processes using AR, VR and digital twin solutions
computer graphics technique where virtual symbols are superimposed to a real image of the external world.
evolution of VR where the user holds Head Mounted Displays / immersed in Cave Automatic Virtual Environment (CAVE structure)
In Vr - no connection between real world and user || In Ar, close contact since only CAD models, writings or symbols are added to the scene
see-through glasses (equipped with a camera and small projector on lenses), or mobile devices such as tablets and smartphones (where the camera is used to frame the external environment and screen is used as output) can be used in AR
Autonomous Robots
example application
opportunities
For example, in the automobile industry, up to 90 percent of drilling is automated1, while aerospace manufacturers still rely on manual hole-making
The Aerospace and Defense (A&D) industry is unique, as it combines complex precision manufacturing with a very large number of manual processes
many assembly process of an aircraft is still done by human worker
challenges
introduction
what?
intelligent robot
Big Data/ Advance Analytics
example application
Skywise
multi-operator platform
offers operators the capability to compile data from diverse sources regarding all aspects of aircraft usage and maintenance
applies advanced analytics and machine learning powered by Palantir to “empower end users to gain new insights from their own data” for Maintenance, Repair and Operations (MRO) activities
largely concern Predictive Maintenance and all of the operational efficiencies and optimization it can offer in parts usage, aircraft downtime and service costs
opportunities
By analyzing data collected from sensors embedded in equipment and workstations, it is possible to spot patterns that may be missed in manual inspection
Digitally lagging A&D companies still using traditional maintenance, repair and overhaul methods can improve asset utilization and uptime by deploying advanced analytics to monitor equipment health in real-time and identify failing components well in advance
challenges
cyber security
introduction
what?
rely on analytics to optimize production
uses data for prediction/ improvement
advantages
up to the minute data - real time decision making
Conclusion
References