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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