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Image of New A320 Structure Assembly Line
Airbus’ highly automated fuselage structure assembly line for A320 aircraft, located in Hamburg, Germany, is responsible for joining single fuselage shells into sections, as well asfinal assembly of single sections to aircraft fuselages. (Image courtesy of Airbus)

Airbus has inaugurated a highly automated fuselage structure assembly line for A320 Family aircraft in Hamburg, Germany, showcasing an evolution in Airbus’ industrial production system. With a special focus on manufacturing longer sections for the A321LR, the new facility features 20 robots, a new logistics concept, automated positioning by laser measurement, as well as a digital data acquisition system. These will further support Airbus’ drive to improve both quality and efficiency while bringing an enhanced level of digitalization to its industrial production system.

“Increasing the level of automation and robotics enables faster, more efficient manufacturing while keeping our prime focus on quality,” said Michael Schoellhorn, Airbus Chief Operating Officer. “Given the enormous success of the A320 Family and the order backlog, we are taking the necessary steps to ensure our production system can match the excellence of our products and that we are able to satisfy our customers’ needs for our single-aisle aircraft.”

For the initial section assembly, Airbus is using a modular, lightweight automated system, called “Flextrack”, with eight robots drilling and countersinking 1,100 to 2,400 holes per longitudinal joint. In the next production step, 12 robots, each operating on seven axes, combine the center and aft fuselage sections with the tail to form one major component, drilling, countersinking, sealing and inserting 3,000 rivets per orbital joint.

Besides the use of robots, Airbus is also implementing new methods and technologies in material and parts logistics to optimize production, improve ergonomics and shorten lead times. This includes the separation of logistics and production levels, demand-oriented material replenishment as well as the use of autonomous guided vehicles.

The Hamburg structure assembly facility is responsible for joining single fuselage shells into sections, as well as final assembly of single sections to aircraft fuselages. Aircraft parts are equipped with electrical and mechanical systems before eventually being delivered to the final assembly lines in France, Germany, China and the U.S.

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