Supporting Precision Aircraft Wing Assembly

Aircraft wing assembly is one of the most demanding manufacturing processes in the aerospace industry. Large aerostructures, strict engineering tolerances and thousands of precision operations require complete process control to ensure every assembly step is performed correctly.

To support this challenge, Spirit AeroSystems implemented the Ansomat Operator Guidance Platform as part of Project LEAD, a next-generation digital assembly environment that combines digital work instructions, augmented reality, machine vision and intelligent tool integration.

The result is a connected manufacturing process that guides operators step by step, validates every action in real time and captures complete production data for full process traceability

Aircraft Wing Assembly Challenges

Manufacturing large aircraft wing structures presents unique challenges that cannot easily be solved with traditional paper-based work instructions.

Spirit AeroSystems needed to address:

• Accurate drilling on large aerospace structures
• Complex assembly sequences requiring strict process compliance
• Limited visibility into operator performance
• Time-consuming downstream quality inspections
• Paper-based work instructions without real-time validation
• Complete traceability for every manufacturing operation
• Consistent quality across complex manual assembly processes

In aerospace manufacturing, even small deviations can result in costly rework, production delays and increased quality risks. Modern aircraft assembly therefore requires digital guidance and continuous process validation rather than relying solely on final inspection.

From Traditional Assembly to Digital Operator Guidance

See how Spirit AeroSystems transformed complex aircraft wing assembly by replacing paper-based processes with an intelligent digital operator guidance platform.

Why Spirit AeroSystems Chose Ansomat

Project LEAD demonstrates how commercially available technologies can be integrated into a single digital assembly environment for aerospace manufacturing.

The Ansomat Operator Guidance Platform coordinates every assembly operation by combining interactive work instructions with connected tools and automated validation.

Operators are guided through each production step while the system verifies actions, enables tools only when required and records every process automatically.

This digital approach improves process repeatability, simplifies operator training and supports continuous quality improvement throughout aircraft wing assembly.

How It Works  -the Ansomat turnkey enabler:

• Augmented Reality guidance highlights the correct drilling locations in real time
• A powered Gantry - A sliding vision system and projector supports accurate work across a 14-meter workspace. It enables repositioning of the camera and projector system
• Automated process tracking through vision: work instructions move forward as the operator has completed tasks correctly
• Instructional videos on pc screen preview upcoming tasks to reduce errors
• Tailored instructions: different levels of instructions and guidance can be set-up based on an individual experience.
• Document Library: Operators are able to access a document library which could contain instructions, standards and videos.
• RFID Tool Register: tools are registered via RFID tags
• Solenoid Control: air tools enablement is controlled via solenoids
• Tooling Pin Control: camera checks that the tooling pins have been removed from storage
• Lifting Solution: A lifting jib allows a single operator to manoeuvre and position the panel
• Tooling Recognition: camera confirms the individual tool ID via QR codes
• Tool integration: Various types of tools can be integrated with the Ansomat system in different ways based on their intelligence
• DC Tools: the tool catprues and transfers torque and angle data to the control system
• EDU Position Control: The EDU (Electronic Drilling Unit) can be enabled based on its position. Tools are disabled until on correct drilling location
• A digital twin validates quality by logging and verifying every operator action

Book a demo

Results

By digitizing aircraft wing assembly, Spirit AeroSystems created a smarter, more connected manufacturing environment that improves both production quality and operational efficiency.

Key Results

• Complete digital traceability for every manufacturing step
• Real-time validation during assembly
• Reduced dependence on downstream inspections
• Improved process repeatability across large aircraft structures
• Automatic collection of manufacturing and quality data
• Better operator guidance for complex manual assembly
• Increased confidence in critical drilling operations
• Higher first-time-right performance
• Greater support for continuous improvement initiatives

The combination of operator guidance, augmented reality and intelligent process validation helps ensure consistent execution while simplifying compliance with demanding aerospace quality requirements.

Project LEAD enables accurate hole drilling, reduces uncertainty, and ensures consistent quality in critical wing assembly operations.

Benefits for Aerospace Manufacturing

Modern aerospace manufacturers must balance flexibility with uncompromising quality and complete process traceability.

The Ansomat Operator Guidance Platform helps manufacturers achieve this by delivering:

• Digital work instructions
• Augmented reality operator guidance
• Smart tool integration
• Machine vision validation
• Full process traceability

To achieve:

• Built-in quality at the source
• Faster operator training & onboarding
• Reduced rework
• Improved compliance with aerospace manufacturing standards
• First-time-right production
• Continuous process optimization