Aviation


Aviation production

Aviation production processes involve the manufacturing and assembly of various components and systems to create aircraft. These processes require careful planning, precision engineering, and adherence to strict quality and safety standards. Here are some key steps involved in aviation production:

Component/Detail Sourcing

Aviation manufacture robotics consist of numerous components, including motors, sensors, controllers, and mechanical parts. Ensuring the availability of high-quality components from reliable suppliers can be a logistical challenge, particularly for specialized or custom-designed details.

In our fast-emerging markets material shortages and substitutions must be considered when producing manufacturing data.

PROMAI’s WizGen supports real-time updates to the manufacturing data by adding, changing, or replacing components and automating new version creation, uploading the updated data to WizShield intelligent production agent making sure the last production processes are manufactured at all times.

Component Manufacturing

Different components of the aircraft are manufactured separately in “design black boxes”. This involves processes such as metal casting, forging, machining, composite layup, and molding. Skilled workers and specialized machinery are employed to shape and fabricate components according to precise specifications. Integrating PROMAI’s WizShield validates all manufacturing processes either on the main integration site or elsewhere, keeps track of the quality yields of each process.

Material Procurement

Once the design is finalized, the required materials are procured. These materials include metals (such as aluminum, titanium, and steel), composites, plastics, wiring, electronics, and various subsystem components.

Assembly

After the individual components are manufactured, they are assembled to build the aircraft. This includes joining the fuselage sections, attaching wings, installing landing gear, engines, avionics systems, and other major components. Assembly may be done on an assembly line, where each aircraft moves through different stations for specific installations. Integrating WizGen advance manufacturing checklists, and WizShield result comparing technology provides zero errors while integration steps are being performed.

Certification and Regulatory Compliance

Before an aircraft can be delivered to the customer, it must go through a certification process. This involves rigorous testing to meet the airworthiness requirements set by aviation regulatory authorities, such as the Federal Aviation Administration (FAA) in the United States.
The aircraft must demonstrate compliance with safety, performance, and operational standards. WizGen automates the creation of checklists for all tests required by regulations, WizShield verifies test are performed accordingly.

Testing and Quality Assurance

At various stages of production, rigorous testing and quality assurance measures are implemented. This includes non-destructive testing (e.g., X-ray inspection, ultrasonic testing) to ensure structural integrity, functional testing of systems and equipment, and overall performance testing. Any issues or defects identified during testing are addressed and rectified.

Maintenance Planning

Airlines and aircraft operators develop maintenance plans based on regulatory requirements, manufacturer recommendations, and their own maintenance programs. These plans outline scheduled maintenance tasks, including routine inspections, preventive maintenance, and component replacements. PROMAI’s WizGen automates the creation of maintenance, fault isolation procedures that are complete and validated.

Maintenance & Fault-Isolation

Maintenance and fault isolation are critical aspects of aviation to ensure the safe and reliable operation of aircraft. Maintenance involves the routine inspection, servicing, repair, and replacement of components to keep the aircraft in airworthy condition. Fault isolation, on the other hand, is the process of identifying and troubleshooting issues or faults in the aircraft's systems or components. Here's an overview of maintenance and fault isolation in aviation:

Scheduled Maintenance

Scheduled maintenance involves routine inspections and servicing at specified intervals. This includes checks of systems, structures, engines, and other components to ensure they are functioning properly and within acceptable limits. Regular maintenance tasks may include lubrication, filter replacement, fluid checks, and system functional tests. Integrating WizShield tracks the different steps and alerts for any maintenance procedure that should be performed, Using WizOpt will maximize operation time of each aircraft component.

Unscheduled Maintenance

Unscheduled maintenance occurs when an aircraft experiences an unexpected issue or failure. This could be due to a system malfunction, component failure, or any other unforeseen event. Aircraft maintenance technicians (AMTs) assess the problem, troubleshoot, and perform necessary repairs to restore the aircraft to airworthy condition. PROMAI’s WizSuite generates complete fault isolation procedures that will assists momentarily isolating the issue or failure save time and time on the ground of the entire fleet.

Fault Isolation

When an aircraft experiences a fault, the maintenance team performs fault isolation to identify the root cause. This involves a systematic process of eliminating potential causes and narrowing down the issue to a specific system or component. Various diagnostic tools, such as built-in test equipment (BITE), computerized maintenance management systems (CMMS), and diagnostic manuals, are used to assist in the fault isolation process. Together with the assistance of PROMAI’s WizSuite and the input from the aircraft self-diagnostic systems fault isolation time is reduced enormously.

Troubleshooting and Repair

Once the fault is isolated, technicians use their expertise and technical manuals to diagnose the specific problem and develop a repair plan. This may involve replacing faulty components, adjusting settings, repairing wiring or connections, or recalibrating systems.
Technicians follow manufacturer guidelines and industry best practices to ensure accurate and effective repairs. WizShield using the data created by WizGen assists in timely troubleshooting of any problem raises.

Inspection and Testing

At various stages of production, rigorous testing and quality assurance measures are implemented. This includes non-destructive testing (e.g., X-ray inspection, ultrasonic testing) to ensure structural integrity, functional testing of systems and equipment, and overall performance testing. Any issues or defects identified during testing are addressed and rectified.

Documentation and Compliance

Throughout the maintenance and fault isolation process, detailed records are maintained to document the actions taken, parts replaced, and inspections performed. These records are crucial for regulatory compliance, tracking maintenance history, and providing a clear audit trail of maintenance activities. WizGen helps generate a digital database for manufacturing maintenance and fault isolation which is easily updatable reusable and maintainable.

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