Aircraft Manufacturing✈️2023: Plane ASSEMBLY – Factory tour Boeing & Airbus plant {Making of...}

foreign [Music] foreign [Music] [Applause] [Music] [Music] [Music] [Music] for everybody [Music] [Music] [Music] thank you students foreign [Music] foreign [Applause] since we are doing [Music] [Applause] [Applause] foreign [Applause] [Music] [Applause] [Music] [Applause] [Applause] [Music] [Applause] foreign [Music] foreign [Music] [Music] thank you [Music] [Applause] [Music] foreign [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] foreign [Music] [Music] [Applause] [Music] [Music] foreign [Applause] [Music] [Music] [Applause] [Music] [Music] um [Applause] [Music] [Applause] [Music] [Music] foreign [Music] [Applause] [Music] foreign [Music] [Music] thank you [Music] [Applause] [Music] [Music] [Music] [Music] foreign before any of those nine days or even a gleam into construction and testing crew's ice however a plane first needs to be designed and made for the first time the design and planning process can take four whole years from initial conception to the time when the first Planes start to be built to begin with Engineers draw up Blueprints and make calculations which are then fed into equations well Once Upon a Time Engineers would have handled all of this themselves today flight teams make use of specialized computers to draw plan and model the design stage following these initial drawings comes the simulation phase at this point the team again uses computers to simulate an aircraft's Performance Based on their calculations and those aforementioned equations some of these equations are highly focused for example a certain equation calculation and simulation sequence can focus solely on the effect of wind upon the plane wind tunnels are also used in conjunction with miniature models of the plane to start getting a feel for it next comes the construction phase it is during this point that all of the components described above were first designed and created the design process will have led to these components either being sketched out from scratch or being selected for compatibility from previously existing models one thing to note about the construction phase is that it typically involves components from many different companies even large-scale companies such as Boeing often buy some of their parts from other companies that specialize in creating a certain type of airplane part now it's time to start putting things together which brings us full circle to the assembly phase with the designs made reality in the plane's component parts constructed or purchased it's time to start making the plane itself before things get to that nine-day cycle of course prototypes have to be built and inspected for quality it is of the utmost importance that these planes be subjected to rigorous screenings and the same goes for the materials used to make them due to its lightweight nature aluminum is the metal of choice for building planes that said this isn't the lightweight aluminum you purchase at the store but a far more heavy duty variant from the first conception and design phases to the final stages of fitting the last components and testing everything out building a single aircraft let alone a whole Fleet of them is a complex process the margin for error is small but the people behind airplane construction are trained professionals the next time you fly think of the immense amount of work that goes into making these Modern Marvels foreign [Music] [Music] [Music] let's begin a look at how airplanes are made by taking a closer look at that nine-day process employed by Boeing manufacturing the 737 Boeing makes use of fuselages and passenger cabins that are made at its assembly plant in Wichita and then shipped for assembly in Seattle this points to another key part of the airplane creation process that it's very much a piecemeal operation different components of an aircraft such as the Boeing 737 are built in different locations and brought together for assembly later what's more these first three days don't even concern themselves with many of the flight Centric features that you probably think of when you imagine an airplane engines navigation means of generating and sustaining lift turning and Landing capabilities none of these are addressed during the first three days instead they are spent installing the electricity Plumbing windows and other basic components of the cabin and fuselage this is also the point at which insulation is added this is incredibly important for keeping the internal conditions on board safe and consistent now things finally start to take on a more plain like shape as the wings and tail fin are added it is of the utmost importance that they be attached with care and precision even the slightest deviation can lead to disastrous consequences for that reason those constructing planes typically use laser guidance technology or similar methods to make sure that the wings and tail are attached with pinpoint accuracy now the horizontal stabilizer is installed to help ensure that the plane is able to maintain balance in the air this is also the start of one of the most persistent and important parts of the plane construction process testing everything out this means that a full plane can not only be built in less than two weeks but the functionality tests for keeping this Modern Marvel in the air are conducted over just four to five days prior to this point most of the planes wiring electrical and mechanical systems have been centered around features including the on-board lighting and Plumbing Systems now the wiring for onboard flight control is added and tested this works the transition from the previous Home Building phase to the latter more technical phase at this point the floorboards are fully installed an element such as the galleys and bathrooms to which those electrical and plumbing setups are to be connected are installed now this is also the stage at which the engines are attached these require their own miniature version of everything that has been discussed so far they too have their shells and physical components built and then have electricity and Engineering materials added later by the time they are formally attached to the plane like the plane itself they have come a long way once the two begin to be connected still more tests are necessary it is vital to ensure that the cables tubed wiring and other components of the engine are connected properly function perfectly and that all of these are in turn connected to the appropriate systems on the plane now the plane is practically finished and the final tests begin this means testing some of the most important components of the aircraft such as the flight deck and the cockpit the latter in particular is extremely complex with modern flight computers being intricate systems that require a great deal of testing to ensure that they are working properly and are in optimal condition this is the end of the line for the plane this is the point at which the company purchasing the plane inspects it tests it out themselves and if they are pleased with how it has been made take it from the factory to their Fleet it's a long process and it's amazing that plane assembly teams are able to fit it all into nine days [Music] foreign [Music] [Music] foreign [Music] thank you foreign [Music] [Music] [Music] fell off ense [Applause] [Music] [Music] [Music] foreign [Music] foreign [Music] [Music] [Music] foreign [Music] [Music] foreign [Music] foreign manufacturers require cost-effective high quality and often highly technical facilities to address these objectives this article provides an overview of several key considerations for the design and construction of plants for aircraft and Associated components everything about an aircraft manufacturing and Assembly Building must be driven by the manufacturing process including process flow process rate and process requirements the building must fully support the process in addition to keeping the weather out the manufacturing process must be well understood at a macro level by the facility planning and engineering team to ensure that inappropriate Building Concept is developed that is integrated with manufacturing needs in addition individual manufacturing areas within the building must be understood on a finite level to ensure that the facility and infrastructure supports manufacturing efficiently following are key considerations related to an assembly building that must be evaluated during planning to establish an appropriate building overall design the manufacturing process type and style may include full line fixed position assembly parallel assembly sub-assembly shops and fishbone assembly all of which will determine the building's size and layout different manufacturing process flows will likely be used for different components or steps within the overall process assembly raid and working process the assembly rate and work in process determined the total building size the building's designers and Engineers will need to know how many aircraft will be built in a week a month or a year the rate also how many units will be in production at one time and in how many assembly positions methods of assembling components methods of assembling components may include bonding riveting Fasteners or even welding these methods determine the necessary support utilities and potential hazards to assembly workers to finding which safety features will need to be incorporated into the building design sizes of component sizes of major components including Wings vertical stabilizers engines main body and Wing joint components are critical these determine the overall size of the facility necessary to accommodate the various components as well as the types of doors their speed and staging space requirements manufacturing tooling fixtures and jigs manufacturing tooling fixtures and jigs are directly related to the manufacturing process space requirements and utilities determining how components move into the tooling or whether the tooling moves to neat components are critical issues if tooling is parked out of the wagering thank you [Music] foreign foreign [Music] [Music] foreign [Music] foreign [Music] foreign foreign [Applause] [Music] foreign [Music] [Music] aircraft can be compared to Leading an orchestra albeit one that involves thousands of participants with a reach that spans the globe when all elements are in harmony the synchronization results in a system that flows and assembles the millions of pieces of our aircraft seamlessly while giving flexibility and Agility to adjust production output in response to market demand each Airbus jetliner built today results from proven expertise accumulated during the company's 50-plus years of leadership and constant dedication and attention from all teams processes are continually refined and make best use of latest Technologies and best practices keeping safety and quality at the top of our priorities orchestrating the industrial flow at Airbus relies on four contributors beginning with manufacturing engineering which co-designs the industrial system in close coordination with engineering and delivers solutions to the company's various manufacturing functions the planning transportation and Logistics teams are focused on designing and deploying integrated standards and solutions with the goals of maximizing efficiency while minimizing environmental impact they take care that all pieces Hearts components are where they should be when they should be and that the aircraft flows through our system smoothly and predictably quality is another critical element with teams ensuring production at Airbus is compliant with industry norms and its aircraft meet the strict standards established by International airworthiness authorities the Assassin Safeguard operations keeping the company culture focused on safety quality and compliance the fourth element involves strategic sourcing and the supply of goods and services as partners and suppliers are considered an important part of Airbus extended family the company's teams are ready to work with them in innovating and identifying areas for improvement ensuring that the aircraft takes good shape months before its pieces enter our factories [Music] foreign has more than 20 manufacturing sites each producing and or assembling different parts of the aircraft which subsequently are shipped to final assembly lines where the complete aircraft takes shape these plants rely on thousands of suppliers worldwide who produce roughly 80 percent of the aircraft before it enters our premises some plants focus on the manufacturing of Elementary parts or so-called metallic or composite to tail Parts tubes pipes panels floors shelves which are used in large quantities in an aircraft others focus on specific functional parts and produce elements that include flaps slats and other high lift devices for the wings horizontal tail planes and Rudders and pylons that connect and support jet engines on the aircraft's wings all these Elementary pieces or components find their way to designated plants where large sections of the aircraft are being put together and equipped with relevant material and systems for electricity fluids air Etc the Assembly of these major airframe components divides the aircraft in five sections the nose the forward section the center fuselage the rear section or act and the wings of course specific locations produce each of these sections fully equipped facilitating their integration when arriving on the final assembly lines in parallel cabins seats and engines also make their way to the final assembly lines the a350 final assembly line is the greenest ever built by Airbus with features including natural lighting wherever possible and a photo will take proof that produces the equivalent of 55 of the power needed for the building to function as well as the recycling of on-site material during its original Construction Hamburg Germany is home to 4A 320 family final assembly lines the most recent one is home to new technologies and processes which were developed in close coordination with employees applying the principles of design thinking this resulted in a modern and much more efficient working environment and the Hamburg experience is now being transferred to other Airbus production lines worldwide a 320 family aircraft are also assembled in Tianjin China where deliveries are made to Asian airlines while Mobile Alabama USA handles the buildup of a 320 family and single Island 220 aircraft for customers in North America [Applause] foreign 500 commercial aircraft during the company's 50-plus year history maintaining a leadership position through a focus on Innovation performance and efficiency the production of Airbus aircraft benefits from a truly International Industrial system with cooperation across the company's Global footprint partnered with a worldwide supply chain Airbus has evolved how its airplanes are built new digital Technologies held to deliver on time while maintaining quality keep flexibility to adjust aircraft production and reduce the impact of manufacturing activities on the environment for improved sustainability looking to the Future Airbus is undertaking a major transformation called digital design manufacturing and services responding to the increasingly competitive Marketplace while also preparing for the next generation of aircraft particularly to meet the company's goal of being the first major manufacturer to offer climate neutral commercial aircraft by 2035 to achieve this ambition aircraft manufacturing and assembly is evolving to bring in new processes tools and jobs for a different way to design and build aircraft while also offering an improved workspace for employees with increased modular design and customization capabilities the next industrial system will leverage higher levels of standardization and commonality of parts and major components enabling new build to stock and build to order decoupled approaches in the factories teams will benefit from even more digital and connected processes tools and devices this will enable just-in-time operations and flexibility to produce and assemble aircraft faster in a cleaner more efficient and even safer environment they will perform activities with more added value supported by robots and using lighter weight tuning this ambitious makeover will enable the Airbus to adapt production rates more rapidly to meet customer demand further enhanced quality increase flexibility in the delivery of aircraft lower the environmental impact by decarbonizing manufacturing activities and reduce costs thank you four Concepts will lead the drivers for airbus's industrial system transformation co-design digitalization of manufacturing processes and tools Robotics and decarbonization code design is all about designing the new programs at the same time as Airbus designs the industrial system integrating the needs of manufacturing and involving the supply chain in this overall process digitalization of manufacturing processes and tools will ensure end-to-end data continuity from engineering to manufacturing this will facilitate data continuity and flow transparent collaboration enabling substantial gains in terms of performance and efficiency lead times standardization and access to operational information the increasing use of Robotics and airbus's Industrial system will substantially contribute to reduce production costs and increase quality standards it will also enable teams in the manufacturing areas to concentrate on added value activities letting robots do the repetitive difficult or low added value tasks increasing safety and overall well-being in the manufacturing areas the industrial system's transformation is also driven by the ambition of Airbus to decarbonize its overall industrial activities further limiting their impact on the environment this includes reducing or eliminating harmful materials and chemicals on the shop floors cutting back on the use of water and energy in manufacturing areas and increasing the use of 3D printed Parts even with reuse materials oh foreign [Music] foreign [Music] [Music] thank you so now oh yeah [Music] [Music] [Music] one more out the wings are one of the most critical parts of any aircraft giving it the ability to actually lift off the ground these long metal fins have to be strong enough to tolerate high levels of stress while also being aerodynamically efficient wings are one of the key parts of any aircraft giving it the ability to take off from the ground and stay in the air using thrust from the engines and airflow around them wings are able to create enough lift to propel the aircraft upwards the key idea of aerodynamics in addition to just the metal structure Wings also feature components such as flaps and slats to further Aid with lift most aircraft wings are constructed from Aerospace grade aluminum and more recently Composite Materials such as carbon fiber both these materials have an extremely high tensile strength ensuring that Wings can sustain far more than any condition seen during any flight composite materials are lighter which is why most wide body aircraft such as the 787 with its curved wings and a350 now favor more Composites over aluminum the wing frame consists of three main components rear Spar main Spar and ribs the Spurs run the length of the wing while the ribs run across the width the required systems like flaps and slats are fitted into this design and later covered with the white panels we see on the outside due to their key function aircraft manufacturers are always looking for a way to make the wings more useful and efficient depending on the plane's weight and size Wing length has to be adjusted while maintaining a high lift to drag ratio however longer Wings also mean more weight and fuel burn balancing all of this is not an easy task but manufacturers have found a way for example the upcoming triple seven features a new longer Wing design to carry more passengers and cargo and offsets this with a lighter weight design the trend is certainly towards longer Wings in the future aside from the metal fins Wings include more Technical Systems too such as computer systems and sensors notably manufacturers have to redesign the number in positions of flaps and slats in every new link flaps are the movable Parts found at the back of the wing slats are on the front allowing Pilots to increase or decrease track depending on the situation curved wingtips have also become increasingly popular in recent years since they reduce track and fuel burn making them a popular fixture of new planes such as the 737 and Airbus while they may seem like a small change wingtips can reduce fuel usage by as much as four to five percent on flights designing the aircraft Wing is only the first step of the process next comes manufacturing both Airbus and Boeing have separate factories producing specific Parts which means there are some dedicated facilities to Just Wings Airbus currently has a production facility in Broad and Wales which makes wings for all Airbus aircraft from the A320 to the A380 Boeing makes most of its wings at its average Washington facility the wings Start From just assembling the metallic frame of Sparks and ribs followed by adding the flight systems and aerodynamic components fuel tanks engine holders and finally the wingtips all of this happens on an assembly line where parts are added and tested being shipped to aircraft assembly plants the wing facilities themselves are massive considering they have to make wings that over 70 meters long in some cases airbuses broaden facilities over 900 000 square feet while Boeing's ever plants are over 1.3 million square feet these plants make everything from the sparse to wiring to assembling the wings themselves the only thing big enough to carry an aircraft Wing is an even biggest aircraft for this purpose both Airbus and Boeing have their own dedicated Fleet of jumbo Freighters designed to carry oversized Parts like wings or fuselage parts Airbus currently operates a fleet of beluga planes to transport wings from Broughton to destinations such as the engineer Toulouse named for their appearance which looks like a beluga whale the manufacturer currently operates five of the older type and one Beluga Boeing has its own jumbo freighter known as dreamlifter since it carries parts of the 787 Dreamliner the dreamlifter is modified from the 747 with four currently in service Boeing uses the plane to transport parts from ever to Charleston and from smaller parts makers in Europe and Asia 100 . [Music] just as an automotive manufacturing the aircraft industry uses assembly lines for manufacturing the production volume is much lower in aircraft but the idea is the same an aircraft manufacturing a series of positions and setbacks are used to indicate the stage of the aircraft assembly for example if 16 positions are used to manufacture an aircraft the 16 position would be the beginning of assembly starting with either the nose section or Wing Spar buildups and the first position would entail the installation of the engines and the cell assemblies the nacelle is the streamlined body which houses the engine position 0 indicates that the plane is out the door and ready for pre-flight inspection in flight test setbacks indicate the stage a sub-assembly or build up is within a position for example a wing assembly naoli Encompass one position but within this position there may be three set regardless of positioner setback assembly work is constantly ongoing even though one position may have more priority than others other positions are simultaneously assembled so that both assemblies will be ready for mating at the proper time the painting and work on the interior of the aircraft hiding seats and cabinets for example are done last as they can vary from aircraft to aircraft the production of an aircraft relies on the precise and Accurate Alignment and mating of each one of the major sub-assemblies for sub-assembly production and assembly mating a series of floor assembly jigs are used these jigs hold support and locate the individual work pieces or sub-assemblies until they can be riveted bonded or bolted in place rigidity of the assembly jigs is critical to prevent Miss element so most of these tools are large and heavy some of the jigs are permanently installed While others are on rollers so they can be moved to the assembly line when needed the quality of aircraft depends on good design documentation and electronic record keeping to meet Federal Aviation Administration regulations and certification requirements the windshields Wing leading edges engines and other critical components must meet the Federal Aviation regulation bird strike requirements before the aircraft is certified for commercial use many different forms and checklists are used throughout the manufacturing process to to tell the history of each coordinate various laboratory tests and standardized Aerospace material specifications have been developed specially for aircraft to check how well-bonded panels have adhered they are placed in a water tank for Ultrasonic testing stress testing is used extensively a section of the aircraft is assembled and then placed in a test fixture which simulates actual use under varying conditions some of the tests are run until the parts fail to see if the design safety factor is acceptable technological change is a major driving force in the evolution of aircraft manufacturing many developments underway involve computerized controls and automation designed to improve economy and quality and lower energy consumption and pollution more assembly operations such as riveting may become completely automated smart sensors sensors with predictive abilities involving fuzzy logic and artificial intelligence are becoming more prevalent artificial intelligence or fuzzy controls enable the sensors to predict changes needed in the settings due to changes in loader production volume in addition to these developments increasing economic and environmental needs will bring further technical refinements to aircraft manufacturing foreign [Music] [Music] foreign foreign processes for aircraft are largely paralleled in the production of satellites their launch vehicles and missiles because minimum weight is critical for all three kinds of products the use of Composites has grown such that it can include the entire structure for satellites and smaller missiles for these vehicles Electronics production plays an increased role in manufacture accounting for as much as 70 percent of the total cost nevertheless the small quantity of satellites necessary even for large constellations and communication systems limits some of the benefits of volume production such as reduced costs although this is not necessarily true of component products that are common to several satellite designs for example sensors instruments small Rocket motors and Communications equipment the final assembly of complete aircraft usually requires a facility furnished with a network of overhead rails on which ride heavy lift cranes capable of moving large portions of vehicles facility sizes governed by vehicle dimensions for example Boeing's plant in Everett Washington is the world's largest building by volume containing some 13.4 million cubic meters and covering an area of 405 000 square meters Airbus Industries final assembly complex in France although smaller with 5.3 million cubic meters is Europe's largest industrial building aircraft assembly normally starts with the joining or mating a fuselage sub-assemblies that have been craned into a supporting fixer as the vehicle is assembled it is moved through a succession of workstations acquiring additional sub-assemblies and accumulating its onboard systems ducts control cables and other interior Plumbing light and medium weight aircraft may be moved on wheeled fixtures Javier aircraft are craned modern large planes and spacecraft often removed via adaptation of the air cushion technique highly compressed air is pumped into the assembly fixture supports and escapes downward through holes the powerful thrust of the escaping air lifts the entire fixture in Vehicle Assembly several millimeters off the floor enough to permit Movement by tractor or human power major assembly steps include the additions of nose and tail sections Wings engines and landing gear on completion of work at the last station the airplane is rolled out of the assembly plant to the flight line for its production flight test a process that involves a thorough checkout of specified performance critical for all Aerospace Vehicles once they are assembled are the methods for ensuring the quality of the manufacturing and assembly processes in the case of aircraft this involves extensive inspections of structural and mechanical items including functional verification of equipment such as control surfaces and systems landing gear operation avionics performance Weapons Systems interfaces and Personnel crew and passenger environmental conditioning helicopters as a special class of aircraft receive inspections that incorporate verification of rotor Drive systems and Associated gear trains [Music] for spacecraft even greater emphasis is placed on functional verification including in most cases Assurance of the performance of all critical operations in thermal vacuum chambers that simulate space in addition since most of its operations are not modifiable to a significant extent once a spacecraft is in Orbit those that are automatically programmed or controlled by computers require highly detailed validation this is preferably carried out with accurate simulations if not actual use of the communication and command links that will be used during the space mission

Channel: Milan's Factory

Views: 1,389,616

Keywords: airplane production, airplane production process, aircraft production, aircraft production process, airplane assembly, airplane assembly line, airplane assembly process, aircraft assembly, aircraft assembly line, airplane manufacturing, airplane manufacturing process, airplane manufacturing documentary, aircraft manufacturing, aircraft manufacturing documentary, aircraft manufacturing companies, airplane factory documentary, aircraft factory, aircraft factory tour

Id: SpTszLHzLLY

Length: 59min 58sec (3598 seconds)

Published: Sat Oct 15 2022