A machining powerhouse

AMJune20Features - Airbus1
AMJune20Features - Airbus1

Airbus has opened a new Manufacturing Milling Centre (MMC) at its Hamburg, Finkenwerder site following a year of construction. Mike Richardson discovers more about the facility from the company’s MMC project leader, Sebastian Dyllong.

 

Airbus recently announced that its new Hamburg-based Manufacturing Milling Centre (MMC) is now fully operational. Brighter, more ergonomic and more interconnected than the previous facility, all processes for the production of wing corner fittings and special parts production for structural assembly are now located under one roof, from the milling shop to surface protection.

The Hamburg MMC stands out for its new system technology, in particular regarding the transfer of data for on-demand production which is now all-digital. This works both interactively and visually, such that staff in the Final Assembly Line (FAL) can see the real-time situation in the MCC and vice versa. Furthermore, this optimised workflow ensures rapid transit between completion, collection of the fittings and their installation at the FAL. In addition, quality inspections, which were previously performed manually are now automated thanks to two robot-assisted measuring units employing 3D scanners.

All under one roof

Also contributing to the MMC’s production efficiencies are two overhead cranes which enable the set-up of two milling machines at the same time. The new location is said to improve the working conditions for the specially qualified employees, with large windows for more light and fresh air. In addition, the surface area of 1,100m2 offers optimised ergonomic conditions and sufficient space for the required logistics areas.

“With the new MMC we wanted to achieve production efficiencies in the A320-Family Programme by having all processes for the production of wing corner fittings and special parts production for structural assembly located under one roof,” begins Airbus’ MMC project leader, Sebastian Dyllong. “The new facility is now interactively, visually and fully digitally connected with the Final Assembly Line so that staff in the Final Assembly Line can see the real-time situation in the MMC and vice versa. Furthermore, the new MMC location also improves the working conditions for the specially qualified employees, with better ergonomics and with large windows for more light and fresh air.”

The new MMC location improves the working conditions for employees, with better ergonomics, larger windows and fresh air

In terms of the kinds of materials and components the MMC is involved in producing, Dyllong says the MMC is involved in on-demand service parts which need a very high reactivity and connection to our internal plant customers.

“On the one hand, we have the special milling process of our unique serial wing corner fittings and on the other, the support of a ‘speedline’ process for e.g. concessions. Within our Research & Technology, we support our internal Additive Layer Manufacturing (ALM) shopfloor for pre-processes and finishing. In the support function of our primary structure, we are talking mostly about aluminium and titanium alloys.”

I’m interested to know whether there is a particular milling machining success story Dyllong can talk about, i.e. reducing tact times, improving quality, closer tolerances, improved repeatability, reduced setup times, improved raw materials handling?

“Yes, there are a lot of improvement topics - not only in regard of the milling machines, but also with the clamping devices, the jigs and tools and the improved ergonomic situation in the new facility with a healthier air ventilation solution. We have an optimised central-cooling lubricant system, which is also connected to our turning machine shop. With the empowerment of additional capacity, we achieve a better line balancing and an optimised value stream in the complete manufacturing process.

“Our CNC machine tool and equipment selections are based on a technical and commercial assessment in accordance with our guidelines. We have realised different technologies from different professional suppliers working in the milling industry. The selection and specification of the equipment was chosen in such a way that automation solutions for future investments can be enabled, e.g. with an automatic set-up system for all jigs and tools.

“We also use a manufacturing execution system (MES), and we have high-tech machines which are generating a lot of data. The key is to use this data for the right things. We are working on an interactive communication with our customers in each process step.”

Layers of potential

What are Dyllong’s thoughts on the disruptive technology of additive manufacturing? With full swarf bins something of a dirty secret on most shopfloors, does he see subtractive machining as a threat, or has he welcomed it with open arms?

“I am confident that additive layer manufacturing has a lot of potential and can be a big manufacturing player of the next industrial generation. From my industrial understanding, an ALM part is not only printed; it often requires pre-processes and the finishing of a milling process - as seen with our own ALM shopfloor.”

A high-precision ‘speedline’ ensures short throughput times for urgent orders and high precision spare parts

So, how much importance does the MMC place in terms of leveraging on Industry 4.0 and the advent of ‘smart tools’ and adaptive machining in general? Also, has Airbus gained any specific productivity benefits and synergies from the implementation and use of robotics automation technology at Finkenwerder?

“Increasing the level of automation and robotics enables faster, more efficient manufacturing while keeping our prime focus on quality. Furthermore, the robots improve the ergonomic situation for many workers, and by working in partnership with them, new competences and skills can be developed.

“We have enormous potential with our new technologies and facilities. A key aspect for us is that we now have to learn to draw the right conclusions from the data generated by the systems. The data and potential systems are the basis for using the possibilities of, e.g. artificial intelligence in NC programme creation. There are many interesting approaches to this currently on the market.”

Finally, what does Dyllong feel are the most important assets of a company like Airbus? For example, is it a defined strategy, its people, its experience, its use of technology, its location or a combination of all these points?

“You need all of these points,” he concludes. “You need a strategy; you need the people and their experience is fundamental. This is the basis for using the right technologies at every place and location.”

www.airbus.com

Company

Airbus

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