Aerospace Industry 4.0 technologies in process optimisation

Manufacturers in all fields are always looking for ways to improve production operations and increase throughput. To achieve this goal, the current workflow must be understood and specific optimisation strategies formed. This is the crucial procedure of process optimisation, a process that must be reviewed again and again, where continuous improvement is measured in micro-steps. The ultimate goal is to improve the company's bottom line and a good way to do this is with the implementation of Industry 4.0 Aerospace technologies.

Process optimisation in the aerospace industry is one of the goals and concerns of manufacturing executives in order to improve operations. However, for many manufacturers, optimisation has yet to bring about real change, and process optimisation is neither an easy task nor a clearly defined, end-point.

Starting point for process optimisation using Industry 4.0 aerospace technologies

It is the continuous methodical review of production processes and, simultaneously, the permanent alignment of new technologies and working methods used to improve the key parameters derived from them. Data-driven technologies and knowledge play a key role in this regard.

Process optimisation starts by identifying the manufacturer's weak points such as material waste, bottlenecks, recurring quality problems, missed deadlines, etc. and asking many difficult questions.

Only by identifying and analysing these inefficiencies can manufacturers set specific targets and milestones for material utilisation and waste, machine availability levels, employee productivity and dozens of other factors that affect costs and production rates.

Real-time data and dedicated technologies play an important role in the efficiency audit process and allow companies to track inefficiencies quickly and accurately, performing automated root cause analysis when problems arise. Using the right tools, manufacturers can identify recurring errors, disproportionate division of labour between workstations, complex production management procedures, etc.

By discovering and enumerating vulnerabilities, manufacturers can set targets that address the ability to increase throughput or reduce costs on a weekly or even daily basis, thus breaking down the concept of production optimisation into actionable steps. Industry benchmarks and actual use cases can be helpful in setting targets.

In general, the methodology of process optimisation in the aerospace sector can be broken down into these steps:

• Detecting and listing inefficiencies

• Analyse and prioritise areas for improvement

• Formulation of a detailed strategy for the optimisation process

• Implementation of such a strategy

• Collecting and analysing results

• Detecting and listing inefficiencies

Industry 4.0 aerospace technology plays a key role in most of these stages and is crucial to the success of this mission.

The following looks at the ways in which Industry 4.0 tools in the aerospace sector are helping industry executives turn process optimisation into a practical reality for day-to-day business.

The role of today's Industry 4.0 technologies in the optimisation of industrial processes

When talking about the digital revolution in the aerospace manufacturing industry, it is often assumed that it is about the replacement of manual work with automated procedures. The reality is that the best thing about digitalisation and technology is the ability to meticulously structure a process and to continuously study and optimise it.

Manufacturing optimisation solutions allow you to study each part of the process in detail and base the steps on real facts. You can detect the exact points where productivity drops, analyse all performance parameters to understand the cause of inefficiency and finally implement the right working methods and solutions to solve the problems.

The following are some concrete examples of the role of the Industry 4.0 technologies in the manufacturing sector for the establishment of new standards in manufacturing processes:

• Digital visualisation and simulationThe creation of a digital twin of the manufacturing production line can help uncover anomalies and test different solutions in a risk-free environment. This technology mimics the behaviour of real problems and solutions to be examined. In the context of process optimisation, production processes that include running simulations in advance can be more efficient. Transparency is a necessity to identify process inefficiencies, but being able to see the entire production plant is impossible unless you have some kind of model.

• Real-time dataYou can study current and potential behaviours using immediate data and witness the positive influences of each change in the process in real time. If something out of the ordinary happens, you are alerted immediately instead of discovering costly movements only after the fact. Improving processes by acting on real-time data can lead to optimised quality, minimised unnecessary costs and other benefits.

• Automated root cause analysis of quality problemsIn addition to real-time alerts, the implementation of advanced optimisation solutions improves post-event analysis capabilities and helps to identify the process failures that caused the problems in the first place, and to adjust the processes as well.

• Predictive perspectiveAI-based solutions allow manufacturers to simulate process steps from data already collected and reflect routine, based on calculations that take into account countless factors inside and outside the factory. Predictive insights are crucial for deciding which processes are most critical to specific goals and challenges, and should therefore be prioritised.

With the Industry 4.0 solutions change is underway thanks to AI and IIoT tools that turn big data into big difference.

Here are some important results of technologies that support process optimisation and are game changers for most discrete manufacturing companies.

• Predictive quality assuranceIIoT solutions based on AI allow manufacturers to predict and alert production managers to potential problems rather than discovering problems when it is too late and delays have occurred, money has been lost, etc. A good enough solution also provides intelligent insights on what to do next. An optimised production cycle takes these problems into account and forms a workflow that avoids them in the first place. Optimising work processes based on technology means identifying where processes are not meticulous enough and can lead to quality failures, and optimising them by adding the right technology to the mix.

• Late work order forecastingAn optimised manufacturing process also includes dealing with setbacks and communicating them to employees and customers. By noticing, for example, that a specific job is likely to miss a certain deadline, managers can reassign work or alert customers and allow them to adjust accordingly. This creates a more responsive and accountable environment and avoids conflict and frustration.

• Prediction and prevention of bottlenecksAgain, by getting an instant, data-driven overview of the entire production line, manufacturers can identify potential bottlenecks or receive immediate alerts when they start. This gives the manufacturer time to readjust and, should these problems recur, implement preventive solutions accordingly.

Process optimisation in the aerospace industry with Industry 4.0 applications

The aerospace industry combines complex precision manufacturing with a large number of manual processes. While in the automotive industry, the vast majority of operations are automated, aerospace manufacturers continue to perform manual tasks and do not exploit the full potential that digital technologies could bring to all business operations.

Industry 4.0 aerospace and smart factory technologies represent a key factor in competitiveness and differentiation. Smart factory solutions modernise the entire range of manufacturing operations, from the shop floor to the top floor, while facilitating seamless integration between plants. They also significantly increase the degree of automation, thereby maximising machine availability, productivity and capacity utilisation, all of which are highly relevant to an asset-, resource- and labour-intensive business such as aerospace and will help justify the ROI of the aerospace industry. implementation of industry 4.0 solutions in the aerospace industry.

Facts when implementing Industry 4.0 technologies in the aerospace sector

A variety of technologies and solutions are involved in the creation of a smart factory, including the Internet of Things (IoT), Artificial Intelligence (AI), Machine Learning (ML), robotics, Augmented Reality/Virtual Reality (AR/VR) and blockchain, all of which are united by the common thread of data, analytics and information.

Data is the key to smart manufacturing. By analysing data collected by sensors embedded in equipment and workstations, it is possible to detect patterns that may be missed by manual inspection. Because everything is connected, shop floor personnel have complete visibility of production operations, including bottlenecks, inefficiencies, maintenance requirements and equipment failures.

Companies with Industry 4.0 aerospace technologies can improve asset utilisation and uptime by deploying advanced analytics to monitor equipment status in real time and identify failing components well in advance. In addition, they can install digital dashboards to visualise data from all production operations that employees can also access remotely with smartphones or tablets and take immediate action in the event of a problem. Finally, senior management can use smart factory data to compare the performance of similar tasks in a single, or even multiple, aircraft assembly units.

In addition to visualising data, a smart factory can virtualise assets and even processes through AR, VR and digital twin solutions. AR and VR facilitate factory due diligence services for the installation of sensors and wireless networks, enabling machine health monitoring and integration on the shop floor. They also simplify complicated assembly line tasks, leading to flawless execution and reduced lead time.

A digital twin seamlessly integrates wireless communication, information and operating technologies to optimise processes, ensure consistent quality and maximise throughput. It allows production flows to be tracked in real time so that bottlenecks in all sub-systems, including waste and energy management, can be quickly identified and resolved. It is also possible to create a digital twin of a physical object, such as an entire aircraft or its parts, and then perform in-depth analysis. This visibility improves understanding of product performance, which in turn can improve design, predict service requirements, and so on.

Robust benefits of using Industry 4.0 technologies

Industry 4.0 aerospace technologies applied to conventional manufacturing can bring large and tangible benefits to companies.

Aerospace companies can leverage an operational efficiency and condition monitoring system to track, detect and analyse, for example, the root cause of process deviations and equipment downtime and thereby improve OEE (overall equipment effectiveness), productivity and customer delivery performance.

The value of a smart factory therefore goes beyond operational excellence or competitive advantage. Predictive analytics, IoT, automation and digital twins can not only improve manufacturing and asset utilisation, but can also support the creation of new business models. To take advantage of the opportunities provided by Industry 4.0 aerospace technologies, companies must adopt a whole-of-enterprise approach from the outset, deploying these technologies in as many operations as possible.