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AUTOMATION GUIDE

For Metalworking Manufacturers in the


Aerospace and Defense Industries
Characteristics and
challenges in aerospace
manufacturing
High quality and traceability be suitable for you, this guide gives
requirements, standards such as insight on how to optimize production
AS9100, variable load sizes from with automation: what are the biggest
millimeters to tens of meters, expensive production bottlenecks to tackle in
and challenging raw materials, small- the aerospace manufacturing, and
batch or recurring few-piece orders – how flexible automation can enable
these are typical characteristics that economical order-driven manufacturing
determine the operating environment down to a batch size of one.
of aerospace and defense industry
manufacturers. Ability to deliver just
a few pieces of a high-quality part at
the right time with full process
Ability to deliver
traceability is a must. The question just few pieces
of competitiveness is: who makes
it the most economically in terms of of a high-quality
production cost per piece, without part in the right
tying capital to inventory and work-in-
process (WIP)? time with full
If you are under consideration on
how to solve these challenges and
process traceability High precision parts in the aerospace and
defence industries require complex machining
whether or not automation could is a must. processes and comprehensive quality assurance.

CHALLENGES
Variables to get right • Do you produce in batches to optimize production cost?
• Do you have significant capital tied in inventory and/or WIP?
• Do you lose orders due to delivery problems?
COST TIED • Do you have scrap or inconsistent capabilities?
PER PIECE CAPITAL LEAD TIMES QUALITY TRACEABILITY • Is your process reproducible?
• Is the history of your delivered parts traceable?

2 3 f a s t e m s . c o m
Status quo: Batch production
Lower cost per piece by making compromises?

Batch production – pros and cons Pro: Lower start cost Con #3: Slower earnings
Batch driven production means producing per part When producing more than what
larger batches of parts than the current order The main reason to produce in batches was ordered, extra capital is tied
PLANNING RESOURCES VALIDATION
backlog consists of. The idea is that the larger is the high production start cost in inventory and revenue realization
the produced batch, the lower the cost per per part. This consists of production becomes slower. There is also a risk of
piece. In the aerospace field where orders are
often recurring, batch production is a natural
planning, start setup, and test drives €€ €€ €€ some parts in the inventory becoming
obsolete, which would mean a direct
to get the part and the quality right.
and its own way a cost efficient choice. That These costs recur every time a new loss.
said, it requires making compromises that are batch is started, regardless of whether
showcased in this spread. the same part has been produced REVENUE IN INVENTORY
• ERP & Excel • NC programs • Setup and
before or not – larger batches mean
• Tools workpiece
€€€ €€€
PROS CONS
less production starts and less
production start costs per part.
• Workholding validation runs
€ €€€
• Raw materials
Lower start cost 1. Higher WIP
per part 2. Longer lead time
3. Slower earnings
Con #1: Higher WIP MACHINE 1 MACHINE 2 MACHINE 3 MACHINE 4
COST PER PIECE

Larger batches naturally mean slower


turnaround. Some process phases
take more time than others, plus there
What if we produce are always surprises like missing
several, even hundreds tools and machine breakdowns
of different parts? on the way. This causes different
BATCH SIZE
batches piling up between the
work phases, increasing WIP
INCOMING ORDERS and tied capital. Here, production
FORECAST, PART A is more driven by available setups
Because of
the upcoming orders, than the urgency of orders, and part
Today let’s optimize cost of the machining capacity is wasted.
per piece by producing
a larger batch.
Order A
Con #2: Longer lead time
In 1 week
The slow turnaround caused by
large batches results in longer
lead times. When an urgent
Order B order comes in, getting it through L O N G E R L E A D T I M E S
fast enough can be challenging.
In 1 month The rapidly changing needs of
customers require flexibility that batch
Order C production cannot offer.

4 5 f a s t e m s . c o m
Full optimization:
Order-driven production
ORDER-DRIVEN PRODUCTION Economical order-driven
ECONOMICALLY production
To lower the cost per piece, many unit cost of producing a single piece
COST PER PIECE, BATCH OF 1 COST PER PIECE, BATCH OF 100
manufacturers are used to producing is the same as when producing
in larger batches. This is because a batch of 100*. Not only is the unit
in the past small-batch production cost lower, order-driven manufacturing
€€€ €€€
has not been economically feasible.
Luckily, today’s technologies offer
a variety of possibilities to optimize
also frees capital from WIP
and inventory, and allows just-in-
time deliveries with shorter lead times.
€ €
production to be economical for Automation also enables effortless and
batches of all sizes, meaning that the first time right traceability reporting.
WHAT DOES IT MEAN
IN PRACTICE?
*In some specific cases the batch
manufacturing may be still more reasonable There are two steps that are needed to On the next page we introduce
than order-driven manufacturing, ie. if there achieve order-driven and economical an example shopfloor the most
are destructive tests or hardening included production: (1) optimization of common bottlenecks
in the process.
the key production bottlenecks, that require optimization to
From batch production and (2) making the production achieve order-driven economical
to order-driven production process repeatable. This requires production. After that we dive deeper
looking at the whole production and in each of these areas, introducing
COST PER PIECE

COST PER PIECE

identifying the exact process phases common challenges, benefits


that could be further optimized. After automation can bring, and the technical
that, the data and integration between things to take into account when
all people, machines, data systems and considering automation as a solution.
resources is inspected and turned into
BATCH SIZE BATCH SIZE
one efficient and flowing process.

Variables to get right


To achieve order-driven
COST
PER PIECE
TIED
CAPITAL LEAD TIMES QUALITY TRACEABILITY
and economical production,
key bottlenecks need to be
optimized.
6 7 f a s t e m s . c o m
Manufacturing process: 2 KINDS AND 2 LEVELS

Common bottlenecks OF AUTOMATION


There are two different kinds
of automation: for low mix,
Example shopfloor high volume (the most known
automation type) and for high
mix, low volume (the focus of
this guide).
The production process can vary If these bottlenecks are tackled, one Each of the listed bottlenecks In the latter type, there
depending on what kind of a can truly manufacture: are presented more in detail in are two levels of automation.
part or product is manufactured. • economically and order-based the following section of this guide. The most basic one focuses on
The process has a couple to hundreds • without tying capital to WIP For each element we share the typical tending a single machine tool,
of different phases which all take and inventory challenges; explain the benefits mostly tackling the bottleneck
different skills, times and resources. • just-in-time / with short lead times automation can bring; and finally list of workpiece transfers and
Typically a single phase is • high-quality parts without scrap the things to be considered when loading – this could be a pallet
somehow optimized but process-wide • with full traceability planning to automate. pool, for example. The second
optimization might be lacking. Let’s level is flexible automation,
take a look at an example shopfloor. which means being able to
The production bottlenecks are automate from 1 to 20 machine
different in every case – typically some tools and other process phases,
are in good condition while others need 1 2
optimization. The six most common PRODUCTION PRODUCTION 6 as well as ensuring that all
machines, people, resources
PLANNING START SETUP MACHINE
bottlenecks are: (1) production and data systems work
TOOLS
planning, (2) production start setup, together seamlessly. Flexible
(3) tool management, (4) transfers and automation makes it possible

MACHINE(S)

MACHINE(S)
TURNING
MILLING
setups between the process phases, to optimize all of the listed
(5) process tracking, and (6) machine bottlenecks gradually or at
tools. once, and flexibility also refers
5 to the automation system being
QUALITY AND 3 extendable for future needs.
TRACING TOOL
MANAGEMENT
Which are your production
bottlenecks?

FINISHING

SURFACE WASHING
4
TREATMENT CMM TRANSFERS
& LOADING

8 9 9 f a s t e m s . c o m
1 Production planning TYPICAL CHALLENGES
• the production plan changes
all the time due to incoming
orders and priorities
Challenges in manual production In contrast, with flexible automation The intelligent production control • unexpected changes
planning (ERP + Excel) are typically an intelligent production control fetches real-time information from in production
related to poor visibility and changes. software is integrated seamlessly to the different data systems and machinery, • lead times are hard to estimate
The production plan is laborious different data systems and production and calculates the optimal production and promises made to the
to make manually, and even more equipment. Now, production can be schedule for incoming orders. It customer are difficult to keep
laborious to keep up-to-date when planned ahead based on real-time: automatically updates the production
new, high-priority orders come in or plan when a new order comes in and FLEXIBLE AUTOMATION
the unexpected happens in production. • Order information with delivery warns in advance if a resource is BENEFITS
The unexpected meaning anything from dates from ERP missing and an order is about to get
missing raw material to a breaking tool, • Information of available delayed. • the production plan
labor shortage, sudden maintenance machinery and resources After production, the intelligent automatically updates based
break or previous orders taking longer (NC programs, workholding, control software reports the completed on real-time information
than expected to produce. tools, raw materials) jobs back to ERP. received from data systems and
With flexible automation and machinery
the intelligent production control, • flexible production: minimize
resources can be shared between the negative effects of machine
different machine tools, meaning that breakdowns and resource
parts can be produced with any suitable shortages by removing
machine tool that has free capacity machine dedication
– not only with a dedicated one. • visibility over production and
This can significantly reduce WIP, upcoming resource needs
shorten lead times and increase • information of order completion
capacity utilization. available even months ahead

WHAT TO CONSIDER?
The intelligent
To achieve flexible production
production control planning, make sure your
updates the automation has the following
integrations:
production plan • ERP
• machinery, regardless
Intelligent production
when a new order of machine brand(s)
control software
schedules
comes and warns in • CAM
• Product Data Management
the production based advance (PDM)
on ERP order
due dates, and if a resource • Tool Data Management System
adapts to any
changes in real time. is missing.
10 1 1 f a s t e m s . c o m
2 Production Start Setup COMMON CHALLENGES
• production is driven by
the easiest available setup
instead of the importance
Manual workpiece set-up changes manufacture next might be made and needed raw material. All these of orders
take a lot of time, even with automatic based on the easiest available setup resources are easily available when • poor reproduceability sets
pallet changers (APC). The key at the time, as opposed to choosing needed. If some resources are missing, challenges for standardizing part
problem is that the manual setup the order that is actually most critical to the system will inform about shortages quality
work is difficult to restore – in the complete. In a way, production might in advance to avoid unnecessary • setup work decreases utilization
worst cases setup work needs to be being driven by setups instead of production stops. and production output
be started from scratch every time, orders. To reduce machine dependent
even when producing recurring In case of recurring orders, flexible jobs, the system can bring the same FLEXIBLE AUTOMATION
parts. Even with the best possible automation system has setups pre- data and resources into any of BENEFITS
documentation, it takes extra effort configured with a systematic approach the parallel machine tools on
and time to start and complete to manage all the information related to the shopfloor, no matter if the part • the system makes sure
manual setup work. Because of setups in production. This information has been previously machined with the everything is in place before
the labor-intensive nature of setup consists of NC programs, cutting same machine or not. starting the production
work, deciding which parts to tools, workholding, work instructions Pre-configured setups mean that • if a resource is missing, the
every item, starting from the first, operator will know in advance
can be run at 100% speed with and have time to react
Manual vs automated setup the same quality. The operator only • setup time shortens significantly
needs to take care of the clamping of or goes down to zero
the parts. This usually means improved • setup is available for any
work ergonomics. Part clamping suitable machine tool
Get the needed Find suitable
tools, measure, workholding can also be robotized when annual
input tool data components and
production volumes get larger. WHAT TO CONSIDER
to a machine tool, clamp them to
put tools in the machine tool If you want to minimize setup
the magazine
times in your production, make
sure your automation is capable
AUTOMATED of:
SETUP • fetching and sending information
MANUAL Bring DURATION: to machine tools (any brand
SETUP the needed FROM SECONDS on your shopfloor)
raw materials TO MINUTES
DURATION: FROM • fetching NC programs from CAM
TENS OF MINUTES TO
HOURS, EVEN DAYS Clamp • saving the workpiece
workpieces instructions related to setup
• storing the list of needed tools
and possibly tool offsets
Setup and workpiece
validation after Automation brings the right NC programs, • handling the raw material
the first run(s). Get the needed workholding, raw materials and tools to logistics
This is an iterative NC program and the machine(s) with all the needed data.
process and might download it to The quality and production speed are • having an interface with AGVs
require multiple runs. the machine tool high from the first run. (in case they are in use)
• storing workholding hardware
12 1 3 and all informationf arelated
s t e m sto. cito m
3 Tool Management CHALLENGES
• machine downtime because
of tool shortages
• high manual intervention and
When the red light of a machine tool and integrating a tool presetting device end, the system automatically brings planning to keep machines running
starts blinking, it is often because of a to the production control software a replacement from a centralized tool and tools up-to-date
tool shortage. The required tool may and machine tools, the tool presetting storage. The reduced need for sister • risk for human errors in tool loading
be completely missing or it has run process can be greatly streamlined. tooling, ability to share tools between and offset writing to machines
out of tool life. This is a daily situation This also removes human errors in the machines and having a proactive • high tool and machine magazine
on the shopfloor – tool shortages tool presetting process. way of maintaining tool life bring investment
are among the biggest time thieves In aerospace manufacturing where great utilization improvements while
in production, constantly stopping the materials are challenging, tool generating savings in tool investment. TOOL AUTOMATION BENEFITS
spindles and requiring action. lives short and the mix of machines Removing manual tool movements
Different software and/or hardware and tools often high, tool maintenance also improves the working ergonomics • know in advance which tool
solutions can streamline tool plays an even more important role. of the operators. is needed, where and when
management. The first step of tool With more flexible tool automation, If the tool lives are extremely short • save time in tool setups
automation is a production control tools can be shared with different and demand for renewed tools is high, • no machine crashes due to
software integrated to the machine machines and delivered automatically tool automation can be extended to wrong tool loading
tools, telling which tools are needed into machines based on real-time optimize the tool setup process (insert • tools can be shared between
in which machine and when. By using needs. When the tool life is about to changes and presetting). machines -> less tools needed, less
machine tool dedicated work, longer
lights-out manufacturing periods
TOOL AUTOMATION GRADUALLY • improved health and safety related
DRIVERS TO IMPROVE to tool maintenance
TOOL MANAGEMENT 1. From reactive to proactive
1 In-advance reports on tool needs: WHAT TO CONSIDER
1. Difficult-to-cut and 2 which tool is needed, where and when
expensive raw materials • integration with machine tools
2. High mix 2. Remove errors from tool loading and/or presetters of any brand
3. A lot of machines Tool presetter and automatic input • integration capability with different
4. Expensive and of tool presets to machine tools tool data management systems
customized tools • when adding a centralized tool
3. Remove machine dedication
5. Health and safety risks storage, think about efficient
and reduce need for sister tooling
due to heavy tools floorspace usage, also vertically
Tools stored in a centralized tool
and repetitive tasks 3 • make sure your tool automation
magazine and robotically transferred
solution is extendable for future
to machines based on real-time needs
needs
(a tool can be shared between many
machine tools)
4
4. Save time from tool setups
Automated tool setup process
5
including insert changes, washing
and presetting

14 1 5 f a s t e m s . c o m
4 Workpiece transfers CHALLENGES
• waiting time between process

and loading phases (WIP)


• careful loading work can slow
down the overall production
• multiple manual interventions
create higher quality risk
A production process of a part can Transfers between different • poor situational awareness
consist of tens, even hundreds of EXAMPLES OF phases happen in seconds. – what happens now and next
different phases. The transfers and PROCESSES THAT The whole production process
loading between different phases play CAN BE INTEGRATED becomes reproducible, and in FLEXIBLE AUTOMATION
a huge role in process efficiency and WITH FLEXIBLE the best case, manual intervention BENEFITS
production quality. It is a trade-off: AUTOMATION from the process can be even
focusing on handling the transfers completely eliminated. • parts can be made ready
• Material management
and loading quickly increases the risk Workholding plays a major role with a single clamp
• Milling machines
of quality problems (uneven quality, when automating the manufacturing • fast transfers enable high
(APC and no-APC)
scrap). That said, focusing on careful process. Different kinds of machinery efficiency
• Turning machines
transfers and loading might slow down need different types of workholding • high precision enables
• Grinding machines
the process. Another consideration is – repeatibility and versatility should high quality
• Finishing
ergonomics - moving heavy workpieces be the main drivers when making • heavy mechanical work
• Washing machines
can be time consuming and is a risk for the investment in workholding removed from operator
• Surface treatments
injuries. equipment. The actual workpiece or • up-to-date working documents
• CMM
Flexible automation makes pallet transfers can be carried out using available for all work phases
• Visual inspection
transfers and setups between a manipulator, AGV or an industrial
process phases precise and fast. robot. With automated transfers, time WHAT TO CONSIDER
It knows exactly how the workpiece or savings and quality improvements can If you want to make your transfers
pallet is positioned when the previous be significant, especially when there fast and precise, make sure your
process phase ends, and handles are many process phases. In addition, automation:
the workpiece or pallet exactly the operator’s daily work becomes • integrates with different kinds of
the same way, every time. more ergonomic without having to machinery, as well as manual
do heavy lifts. and stand-alone process phases
• has a reliable and versatile
workholding solution to work
well together with automation
How many transfers between • is able to show work instructions
different phases are needed to the operators
in your process?

16 1 7 f a s t e m s . c o m
5 Quality, Traceability CHALLENGES
• demand for full part traceability

and Liability and high quality


• traceability reports cause
a lot of paperwork
• quality assurance and
traceability make ~15–30%
In the field of aerospace, where (introduced in sections 2 and 4) saves operator from having to put extra effort of the total production costs
security and safety are at the very significant time and helps in producing into tracing and ensuring that the • price of failure – the cost of
heart of business, part quality and high quality, starting from the very first documentation is correct. The report when not achieving the first time
traceability are a must. Typically part. is gathered together automatically by right
the problems in these areas are collecting all the needed data from the • liability issues
caused by the irreproducibility TRACEABILITY process, and can be easily exported to
of a process. In the worst case Traceability is not only a matter of other systems like QMS. AUTOMATION BENEFITS
a quality problem could lead to a larger security or liability – it also allows
scale liability issue. Flexible automation companies to improve their processes. • a reproducible process enables
can help in enabling constantly high The main challenge in traceability high part quality and first time
quality and reduce the paperwork reporting is that it requires a lot right
related to traceability reporting. of manual work and has a risk for • easier fulfillment of AS9100
mistakes. A high amount of paperwork is requirements
QUALITY needed on the factory floor to generate • easy and reliable traceability
A reproducible process is key to the needed documents, and typos reporting
having constant high quality that or missing information can make
meets the industry standards. the report incomplete. WHAT TO ENSURE
Collecting and storing all the correct Flexible automation with an • make sure the system can
data on tooling, NC programs, setups intelligent control software has built- store all the manufacturing
and work instructions automatically in traceability reporting, freeing the data for later use
• ability to collect all the
traceability data without causing
extra work for the operators
• easy data exporting to other
systems such as QMS
AS9100 TRACEABILITY REQUIREMENTS PART: XYZ • make sure your automation
TYPICALLY INCLUDE system is AS9100 compatible,
• Serial no: 25455448
AND can support you in AS9100
• the part identification through the whole part/product life • Operation: 10 - Turning
related process optimizations
• ability to trace all the parts from the same batch • Machine used: MC3
and documentation
• ability to trace all the components of an assembly • Program: 3445
• a part production record, including: what has been done, by whom, • Machining time:
when, which machines, NC programs and tools used, and quality con- 3h 12 min 50 s
trol / inspection reports • Status: Machining completed

18 1 9 f a s t e m s . c o m
6 Machine tools SHORT-VIEWED MACHINE
INVESTMENT MAY LEAD TO
• dedicated machines
– what happens when
The machine selection process thought out before hand. In addition, In which size of an envelope a machine breaks?
starts from the parts or part families in the ideal world you would want to would all of your parts fit? • an increased investment need
that are produced. Oftentimes previous make sure that all machines are able Do you need many envelopes? for machine tools
machine investments have been made to produce any of the parts. Benefits • increased floorspace needs
based on the machining needs at the of purchasing similar machines that D • tool setup challenges when
time, as opposed to also planning are able to run as many parts as sister tools are in use
ahead. In the future, this can then result possible give flexibility in job resourcing
in a situation where machines are not by removing the dedicated machines, WITH GOOD INVESTMENT
suitable for new parts, and the need in operator resourcing by making sure PLANNING
for new machines arises yet again. everyone can use any machine, and W
H • the long-term investment
There are many shopfloors that are reduces the maintenance and sparepart
full of different machine types, each costs. Also the amount of clampings for machine tools and
producing dedicated parts and having need to be thought out: in general, the maintenance costs reduce
specialised operators. Sometimes it 5-axis machines give greater flexibility • operator resourcing
is the best way to go, especially with with a reduced need for reclamping. becomes more flexible because
different raw materials and variable Hard materials cause a large more people have skills
THINK ABOUT to run the same machine
part sizes, but oftentimes one machine consumption of cutting tools. This YOUR MACHINE TOOL
could produce many more different should be considered when deciding the • the floorspace is better utilized
RESOURCING with less tools that are all
parts than it is used for. tool magazine capacity of each machine
• do you need dedicated capable of performing as many
When planning a machine tool tool. A big enough magazine allows for
machines or could you utilize jobs as possible
investment, the future business sister tools that enable longer lights-
the “envelope” model to
possibilities and resource- out manufacturing periods. However, if
improve machine utilization? WHAT TO CONSIDER
efficient production should be tool life is short and there are many
• when a machine breaks or
also considered. The range of part machine tools, tool automation with one • similar machines to increase
an operator is on vacation,
sizes, the “envelope” in which all centralized storage for thousands of flexibility and reduce
do you have similar
produced parts fit into, need to be tools and the ability to share and bring maintenance costs
machines or people with the
tools to machines can be a profitable • 3-, 4- or 5-axis machine, what
right skills to substitute?
investment (presented in section 3).
Similar machines • is it better to save on
is suitable for your current and
future needs?
machine costs and increase
that are able to run the amount (and time)
• large enough tool magazines
to also enable the utilization of
as many parts of clampings or the other
sister tools / tool automation
way around?
as possible • what is your tool and
to share the tools for different
machines
give flexibility in sister tool need – should
• machine interfaces for
you purchase larger tool
resourcing and reduce magazines or a centralized
integration with different
production data systems
maintenance costs. one?
• operator skillsets on machine
control technologies
20 2 1 f a s t e m s . c o m
Summary CHECKLIST – REQUIREMENTS TO CONSIDER
WHEN PLANNING TO AUTOMATE

Production planning Workpiece transfers and loading


In this guide we presented common • >90% spindle utilization
challenges in the field of aerospace and • cycle time down by 58% ■ integrates with ERP, machinery ■ integration with different kinds
defence manufacturing, the variables • ability to produce the whole (regardless of brand), CAM, of machinery and extendability
to get right to ensure successful weekend lights out, even batch PDM and Tool Data Management for futher needs
business, and typical bottlenecks. As sizes of 1 Software ■ ability to also add also manual
demonstrated, all of this can be tackled • yield rates of 99.5% ■ predictive scheduling and work cells and stand-alone
with automation to make production • improved employee retention adapting to changes based machines, and give instructions
processes flexible, economical and on real-time data to the operators
reproducible. ■ visibility over production and ■ reliable and versatile workholding
A comprehensive automation accurate order completion forecast solution to work well together
project definitely takes a lot of with automation
To read more on how your
Production start setup
evaluation and preparation work peer companies have solved
but when done well, the results for their productivity challenges ■ integration with machinery and Quality, traceability and liability
aerospace manufacturers have been with automation, go to data systems with production ■ ability to store all the
remarkable: documents manufacturing data for later use
fastems.com/aerospace
■ save the setup-related information: ■ ability to generate traceability
workpiece instructions, the list reports automatically
of needed tools and their offsets, ■ integration to QMS
and workholding hardware ■ AS9100 compatibility
with the data
■ handle raw material logistics Machine tools
When done well, What are your production
bottlenecks? How to find and
and integrate with AGVs ■ similar machines to increase
(in case they are in use) flexibility and reduce maintenance
the results of flexible measure them? Could they be solved costs
automation for with automation? How to make your Tool management ■ 3-, 4- or 5-axis machines,

business can be
automated process AS9100
compatible? We at Fastems are
■ integration with machine what are the most suitable for your
tools and different tool data current and future needs?
remarkable.
happy to help solve any productivity management systems ■ tool magazines large enough to
challenges: fastems.com/contact
■ tool presetter and integration to it also enable utilization of sister
■ when considering tool magazines tools/ tool automation to share
or one centralized tool magazine, the tools for different machines
efficient use of floorspace, also
vertically

COST TIED
PER PIECE CAPITAL LEAD TIMES QUALITY TRACEABILITY

22 2 3 f a s t e m s . c o m
Read how aerospace and
defense manufacturers have
solved their productivity
challenges with automation:
fastems.com/aerospace

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