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 one of the most critical components of an aircraft engine and must be assembled with extreme precision. It contains multiple critical fasteners that must be tightened in a predefined sequence using specific torque parameters. In addition to controlled tightening, operators must follow an exact assembly workflow while ensuring every component is correctly positioned and verified.
Traditional work instructions could not actively prevent errors such as:
Safran needed a digital solution that could actively guide operators, verify every action in real time and create complete production traceability.
A key assembly step involves tightening 18 bolts in a strict cross-sequence pattern.
If the tightening sequence is not followed correctly:
Despite detailed work instructions, human errors still occur, especially during repetitive operations or when performed by less experienced operators.
Importance of Cross-Sequence Tightening
Cross-sequence tightening is essential to ensure:
Improper tightening can pull one side of the component down harder than the other, leading to mechanical defects that are unacceptable in aerospace applications.
Objective:
Ensure correct bolt position and tightening order throughout the entire assembly process.
| Traditional Assembly | Ansomat Digital Error-Proofing |
| Paper or screen-based work instructions | Interactive augmented reality guidance |
| Operator determines next assembly step | Software guides every assembly step |
| Manual verification of bolt sequence | Automatic sequence validation |
| Limited visibility of assembly status | Real-time process monitoring |
| Errors detected during inspection | Errors prevented before they occur |
| Manual documentation | Automatic digital traceability |
| Higher operator dependency | Standardised, repeatable assembly |
Ansomat's Digital Operator Guidance solution orchestrates the entire assembly process, guiding the operator through every step while validating each action in real time. By combining augmented reality, machine vision, controlled tightening and digital process control, the system prevents assembly errors before they occur and automatically records every operation for complete traceability.
| Step | Technology | How it works | Validation |
|---|---|---|---|
| Project next bolt | AR Projection | The system projects the next fastening location directly onto the workpiece, clearly indicating the correct bolt and tightening sequence. | The correct bolt is highlighted, eliminating uncertainty and reducing the risk of selecting the wrong fastener. |
| Position tool | Machine Vision | Before the tightening tool is enabled, the vision system verifies that it is positioned on the correct bolt. If the wrong location is detected, the tool remains locked and the operator is guided to the correct position. | Correct tool position is confirmed before tightening can begin. |
| Tighten bolt | Smart Tightening Tool | The tightening tool automatically applies the predefined torque and angle program for the specific fastener while monitoring the tightening cycle in real time. | Every tightening result is validated against the required specification and recorded for traceability. |
| Finish process | Camera Inspection | Once all tightening operations are complete, an inspection camera captures a high-resolution image of the finished assembly to verify the final product condition. | Inspection images are automatically stored as part of the digital production record. |
| Complete assembly | Digital Process Control | The software verifies that every required assembly step has been successfully completed before releasing the product to the next production stage. | Complete process history—including operator actions, tightening data, inspection results and timestamps—is stored to provide full production traceability. |
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.
