Aerospace 4.0 – why we need it

Dan Lewis, market sector vice-president of aerospace at Plexus, discusses the importance of new technologies.

The idea of a 4.0 is not a new one. In fact, Industry 4.0 has been in place for some time and Aerospace 4.0 is a part of this next industrial revolution. It is about the building of the digital enterprise and will, as such, play a key part in revolutionising the industry.

The question is, just how important will Aerospace 4.0 be and how will it enable the industry to evolve? Aerospace 4.0 essentially applies all the new digital technologies entering the electronics manufacturing industry but through the lens of the aerospace sector. These new technologies include Big Data, 3D printing, mobile and edge computing, augmented reality, machine learning and the Internet of Things.

Prior to these, aerospace companies had issues providing data back to the product’s design, maintenance and manufacturing processes autonomously and in real-time, and from all parts of the value chain - including in-service data. Today’s digital technologies ensure product life cycle data is available in real-time and is adaptive and optimised.

Aerospace companies need to stay current in order to compete in the global market. To achieve that, they must develop products faster, cheaper and better. The only way to ensure that is attainable is to embrace the new digital tools that Aerospace 4.0 has to offer.

By adopting this digital approach, companies can avoid past issues and move to a more effective way of working that meets deadlines and satisfies customers. The tools that form Aerospace 4.0 will enable companies to reduce costs, improve quality, cut down inventory, up the work rate, minimise waste, improve time to market and increase the opportunity to introduce new products.

Cutting down the iterations

One specific area where digital technologies can have a significant impact is with the reduction of design iterations for new product developments. By taking into account the real-time data provided by all aspects of the value chain, the design team can be better informed as to the optimal design approach.

Design iterations can be costly. In aerospace, this is particularly true. Much of the time and cost of a new product launch is in the effort to qualify the product on actual airframes. Once this qualification starts, additional design changes are difficult to make, as they may drive a costly requalification process. This is why it is imperative that the design team hits the mark with their design iterations. Building in the knowledge from a robust information store as to how prior products have fared in the field provides invaluable knowledge. This empowers the design team to ensure that the design that goes out for qualification is the right design.

Data analytics are key

Another area where digital technologies can have a significant impact is on the production line. It is here that data analytics can prove key. In the past, the aerospace manufacturing process involved moving products from the production line, piece by piece and then, once all assembled, going through to expansive testing. This contributed to significant inefficiencies; if the product did not work correctly at this stage, it would have to be re-worked or re-produced and re-tested. All taking time, costing money and adding significant delays.

Now, with the introduction of new production line technology, manufacturers have a real-time view of each part of the process. This helps to minimise downtime and establish real-time feedback and testing at every stage of the production process. The constant visibility into the production status means that no time or resources are wasted as testing takes place during each section of the production process rather than at the end.

This is all aided by data analytics which allows for data to be fed back to a control system. This enables more precise and real-time decision making. The technology adds value to the production line process and it is easier, and cheaper, to address a problem proactively rather than when it’s much more costly to remediate.

Time can be costly

Investing in digital technology may appear expensive in the short term. However, as the technology helps aerospace manufacturers to avoid issues such as testing mistakes and wasted time – ultimately resulting in increased costs – these digital technologies will prove cost effective in the long run. Today, as these technologies continue to develop, we are starting to see a reduction in the outlays required and the adoption rates are increasing.

As designers and manufacturers adopt and adapt to these technologies, they will use them to create new insights and new ways of bringing ideas to the market. While there are process efficiencies to be gained, Aerospace 4.0 truly is evolving the way a product is brought to life: from digital factories that use real-time analytics for continuous decision making to blockchain technology that allows for full “nuts to finished aircraft” supply chain transparency.

Ultimately, Aerospace 4.0 impacts not only the operations side of the business, but the user experience as well. From enabling and improving the capabilities of a ‘connected aircraft’ that allows for customised entertainment options for the passengers from take-off to touch-down, to the ability to have real-time data analytics for the crew to ensure continued safety throughout the flight, the ability to connect data and platforms will allow for experiences and dependability previously unthought of in the aerospace industry.

The challenges ahead

That’s not to say that embracing Aerospace 4.0 won’t bring up challenges. Companies are going to have to adapt the ways in which they work and the way they train their workforces. As Aerospace 4.0 comes into play, more firms are going to have to think about how they will re-skill current employees whose roles will be changed as the emerging technologies are adopted. This should not deter companies from embracing the digital technologies that Aerospace 4.0 will bring, as the workforce of tomorrow will expect to enter an organisation that uses the latest technologies. So, in order to attract the best talent, digital transformation must be embraced.

Aerospace 4.0 is set to change the way the industry operates. New digital technologies will enhance the manufacturing operations by saving time and money. They will aid the creation of new, ground breaking products. It is of paramount importance that companies working in the aerospace sector embrace and adopt digital technologies in order to stay relevant and keep up with other markets. Aerospace 4.0 should no longer be a desire: in 2019 it is a necessity.

www.plexus.com

https://zunum.aero