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In aerospace manufacturing, even the smallest assembly error can have significant consequences. Every component must be assembled according to strict procedures, with complete traceability and verification to meet the industry's demanding quality standards.
During the assembly of a critical aero booster, Safran required a solution that could eliminate operator errors while maintaining an efficient production process.
Ansomat implemented its Digital Error-Proofing solution, combining augmented reality guidance, machine vision, controlled tightening and real-time process control to ensure every assembly step is completed correctly the first time.
The aero booster is a critical aircraft engine component that requires precise and repeatable assembly. Every critical action must be performed in the right sequence, in the right position and with the right process parameters.
For fastening operations, this means controlling the fastener position, tightening sequence, torque and angle, while ensuring the operator follows the correct assembly workflow.
Traditional work instructions alone cannot prevent wrong sequences, missed steps or positioning errors.
Safran needed a solution that could guide the operator, control and verify critical actions in real time, and provide full production traceability.
De aero-booster is een van de meest kritische onderdelen van een vliegtuigmotor en moet met uiterste precisie worden gemonteerd.
Een belangrijke montagestap bestaat uit het aanhalen van 18 bouten in een strikt kruiselings patroon.
Als de volgorde van het aandraaien niet correct wordt gevolgd:
Ondanks gedetailleerde werkinstructies komen menselijke fouten nog steeds voor, vooral bij repetitieve handelingen of wanneer deze worden uitgevoerd door minder ervaren operatoren.
Het belang van kruislings verschroeven
Verschroeven in kruislings verband is essentieel om te zorgen voor
Verkeerd aandraaien kan de ene kant van het onderdeel harder aantrekken dan de andere, wat leidt tot mechanische defecten die onaanvaardbaar zijn in luchtvaarttoepassingen.
Doel:
Zorgen voor de juiste boutpositie en aanhaalvolgorde tijdens het gehele assemblageproces.
Samengevat transformeert deze oplossing een kritische, foutgevoelige handmatige bewerking in een geleid, foutbestendig en volledig traceerbaar assemblageproces, wat meetbare voordelen oplevert voor kwaliteit, productiviteit en personeel.
All tools and technologies are connected in one controlled workflow, guiding the operator, controlling critical operations, verifying actions and recording every step.
| Integrated technology | What it does |
| Barcode Scanner | Identifies the product and automatically loads the correct variant and assembly program. |
| AR Projector | Projects work instructions and visual guidance directly onto the work area, showing the operator what to do and where. |
| Electric Nutrunners | Controls fastening with the correct program and provides real-time torque and angle feedback. |
| Machine Vision | Verifies operator actions and component presence, and captures pictures as quality evidence. |
| RTLS / Tool Positioning | Monitors the tool position to ensure operations are performed at the correct location. |
| Full shop floor traceability | Controls the workflow, validates each step and records all process data for full traceability. |
The complete solution is integrated with Safran Group's IT systems and requirements, ensuring seamless data exchange with the existing production environment.
Together, these technologies turn work instructions into an active, error-proof assembly process. The operator is guided through each step, connected tools are automatically controlled, critical actions are verified in real time, and the complete process is recorded.
Right instruction. Right tool. Right action. Verified result.
Following implementation, Safran achieved significant improvements in assembly quality and process reliability.
Operators are digitally guided throughout the complete process, preventing incorrect actions before they occur.
Every fastener is tightened using the correct program, sequence and specification while automatically verifying torque results.
Augmented reality guidance reduces uncertainty and simplifies complex assembly procedures, enabling operators to work more efficiently.
Every assembly action, tightening result and inspection is automatically recorded, supporting aerospace quality standards and full product traceability.
Digital workflows can easily be updated for new product variants or process improvements without extensive operator retraining.
In aerospace manufacturing, quality cannot depend solely on operator experience. Digital Error-Proofing transforms manual assembly into a controlled, verified process where every action is monitored and validated in real time.
By combining augmented reality guidance, machine vision, controlled tightening and digital process control, manufacturers can eliminate assembly errors before they occur while improving productivity, consistency and compliance.
Safran's Digital Error-Proofing solution enables:
Whether you manufacture aerospace components, automotive systems or other safety-critical products, Ansomat helps manufacturers eliminate manual assembly errors through digital error-proofing, augmented reality guidance, machine vision and intelligent process control.
