Safran - Digital Error-Proofing for critical aero booster assembly
Challenge for critical component tightening
The aero-booster is one of the most critical components of an aircraft engine and must be assembled with extreme precision. A key assembly step involves tightening 18 bolts in a strict cross-sequence pattern.
If the tightening sequence is not followed correctly:
Uneven load distribution can occur
Components may distort or warp
Assembly quality and safety are compromised
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:
Even distribution of clamping forces
Prevention of localized overstressing
Dimensional accuracy of the assembled booster
Long-term reliability and safety of the engine
Improper tightening can pull one side of the component down harder than the other, leading to mechanical defects that are unacceptable in aerospace applications.
Proposed Solution
Tool Position Control – Cross Sequence Assurance
Objective: Ensure correct bolt position and tightening order throughout the entire assembly process.
Key Features
Augmented Reality bolt sequence projection The correct bolt tightening sequence is projected directly onto the booster, guiding the operator step-by-step.
Visual feedback is provided, guiding the operator to the correct position
Real-time error prevention Incorrect bolt positioning is immediately detected and flagged, eliminating the risk of tightening the wrong bolt.
End-of-process visual inspection A high-resolution image of the completed booster is taken at the end of assembly for:
Quality assurance
Full traceability
Audit and compliance purposes
Full torque and angle traceability Torque and angle data are recorded for every single bolt, ensuring complete process documentation and compliance with aerospace standards.
Elimination of tightening sequence errors Incorrect bolt tightening is effectively prevented.
Improved first-time-right quality Reduced rework, scrap, and inspection costs.
Reduced dependency on highly skilled operators The system enables less experienced operators to perform complex tasks reliably.
Increased workforce flexibility Facilitates workstation rotation, reducing operator fatigue and repetitive strain while improving productivity.
Enhanced quality, safety, and traceability Supports Safran Aero Boosters’ commitment to aerospace excellence and regulatory compliance.
In summary, this solution transforms a critical, error-prone manual operation into a guided, error-proof, and fully traceable assembly process, delivering measurable quality, productivity, and workforce benefits.
