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To remain competitive in the fiercely contested North American automotive industry, the New United Motor Manufacturing Inc. (NUMMI, Fremont, CA) assembly plant, a joint venture between Toyota Motor Corp. (Aichi Prefecture, Japan) and General Motors Corp. (Detroit), has rededicated its efforts in lean manufacturing during the past few years by applying key tenets of the Toyota Production System (TPS). 

With thousands of fastener locations that need to be drilled and filled to complete a plane, drilling and fastening remain the largest areas of opportunity for automated robotics applications in aerospace. New developments are also making robots more attractive than ever in the aerospace and defense space—especially improved rigidity and accuracy in the robots themselves.

The classic manufacturing conundrum is how to make products quicker, cheaper, and better.

The aerospace industry continues to increase its use of composites, a phenomenon that’s pushing academics, trade groups and manufacturers to research and develop methods to enhance the techniques and tools for using the materials.

New ISO safety specification helps automation developers design safer robots for close encounters on the factory floor

“Metrology and its relationship to manufacturing is rapidly evolving,” Ken Woodbine, president, Wilcox Associates, a brand of Hexagon Metrology (North Kingstown, RI), recently observed. “We are seeing larger quantities and faster speeds of measurement data collection. The next challenge is what to do with all that data.”

I traveled to Toyota headquarters in Japan with Jeff Liker for a research project. We wanted to learn more about the engineering and collaboration that created the Toyota New Global Architecture (TNGA), the strategy and innovation behind hydrogen vehicles, and how they had adapted and improved their development system to meet the increasing demands of the ultra-competitive global auto industry.

Modern manufacturing is rapidly adopting model-based definition (MBD). When employing an MBD strategy, the CAD model becomes more than the nominal to which all parts are measured and inspected against. MBD keeps the all-important digital thread intact—from design to manufacturing to inspection and quality reporting.

To run factories at optimal efficiency, plant managers need to mine real-time shop-floor operational data as fast as possible, to quickly determine where and when any manufacturing process bottlenecks occur. With today’s shop-floor data management software and related hardware solutions, manufacturers can leverage more key production performance data than ever in order to fine-tune their manufacturing processes.

As additive manufacturing emerges from a long infancy, the industry is grappling with a key challenge: A file format and design tools from the 20th century are being asked to do 21st century jobs.