Future manufacturing will combine digitisation, sustainability and talent

Since the company was founded in 1916, Boeing has been a worldwide reference in aeronautics, defence and space. Based on its role as an outstanding leader in the area of technological innovation that helped aviation to evolve over the years, the company has devised sustainable solutions and collaborated with international partners to be more competitive and open up new possibilities for the future of the aerospace sector. In this interview, Carlos Bello-Larroche, a Manufacturing Technology Integration Engineer at Boeing Technology Innovation, shares his views on the challenges currently faced by a manufacturing in aeronautics by describing the impact produced by new technologies and the talent needed to boost the sector’s future.

 

1.- What challenges have you observed in the industrial manufacturing sector and, more specifically, in the area of aeronautical manufacturing?

Most of my professional goals have focused on identifying technologies used to optimise manufacturing processes that are not always tangible. For instance, and although technologies based on artificial intelligence (AI) and machine learning (ML) offer numerous opportunities, they also pose significant challenges.

In addition to the progress made in the area of AI it is crucial to develop robust cybersecurity coverage to prevent the loss of intellectual property and avoid cyber attacks that could harm the aeronautical industry’s digital ecosystem.

As regards data collection and interpretation, it is essential to establish standardised digital processes so that equipment and component manufacturers can use the same language when communicating with each other so the supply chain may operate efficiently and reach out to all the suppliers of raw materials and companies building airplanes. To achieve this goal a joint effort is required involving all organisations, government bodies and private companies alike, to set up a joint and efficient ecosystem that will boost manufacturing in the future.

Boeing is facing these challenges by developing new technologies at its Boeing Technology Innovation centres in Europe. These technologies are fully in line with the company’s industrial strategies in areas such as systems engineering, automation and materials.

Our team in Germany specialises in drilling technologies and is studying how assembly operations involving primary structures can be optimised. Our colleagues are also simulating material models and optimising qualification processes for materials. We are currently making progress in the United Kingdom in the area of metal shaping and machining technologies that feature additive metal manufacturing capabilities and new high cadence resin infusion processes in the area of composites. In Spain, digital tools based on AI and ML systems are being developed to improve manufacturing processes.

2.- Which technologies do you think will revolutionise production processes and equipment to meet these challenges?

Nowadays, industrial manufacturing, especially in the area of aeronautics, is being transformed by several emerging technologies. Artificial Intelligence optimises processes by analysing large volumes of data, by improving the quality of a product and by providing predictive maintenance capabilities. Additive manufacturing or 3D printing do not only make it easier to produce complex and customised parts but also reduce waste and enhance sustainability.

The Internet of Things (IoT) improves equipment connectivity and allows data to be compiled and exchanged in real-time data compilation, a feature associated with unprecedented capabilities in terms of monitoring production runs. Thanks to collaborative robots, advanced robotics increases efficiency, reduces occupational risks and quickly adapts to a broad range of tasks.

Boeing is actively working with all of these technologies for the purpose of playing a leading role in the transformation of aeronautical manufacturing by optimising processes, improving the quality of end products, enhancing sustainability and guaranteeing traceability in the supply chain whilst simultaneously adapting to changing market demands.

3.- In this scenario, what role do you think will be played by Artificial Intelligence and humans?

It is fundamental to establish an effective and complementary relationship between Artificial Intelligence and humans in the area of aeronautical and industrial manufacturing. AI acts as a powerful tool that can accurately process and analyse large volumes of data much faster than any human being which means that processes can be optimised and improvements can be made in terms of product quality and predictive maintenance, an area in which AI can anticipate machine failures to reduce downtimes and maintenance costs. I do think, however, that the role to be played by humans will be essential. Workers can contribute with their creativity and innovation, two skills that AI cannot replicate (at least for now) and which are crucial when designing new products and making critical decisions that require ethical and strategic judgements.

As the future of manufacturing requires a collaboration between AI and workers, training and upskilling must be provided so that operators may use these tools effectively. Supervision by humans is essential to ensure that AI systems are fully in line with the company’s goals and are used ethically.

4.- How would you rate the contribution made by technology centres such as Tekniker with regard to R&D&I in this area?

The contribution made by technology centres such as Tekniker in the area of aeronautical and industrial manufacturing is essential. Thanks to their extensive know-how, these organisations play a pivotal role when performing advanced research in areas such as automation, additive manufacturing and artificial intelligence to generate new methodologies and processes that can be implemented by the industry. Technology centres have also served to reinforce collaborative actions between companies and academics aimed at boosting technology transfers and implementing innovative solutions.

5.- Tekniker is the organiser of a seminar in Madrid called “The future of industry: human-centred manufacturing. How helpful do you think initiatives like this are for the sector?

I believe that seminars of this kind offer a number of key benefits to the manufacturing sector that are essential to become more competitive as they provide a platform where knowledge can be exchanged between experts and professionals to further disseminate trends and emerging technologies. They can also boost networking and collaborative actions between companies, research centres and start-ups to eventually deliver specific projects. Events of this nature allow companies to present innovations, given them more visibility and identify opportunities to improve competitiveness. The seminar also features workshops and lectures with information covering a number of key areas to keep professionals abreast with current developments. In short, I believe that for anybody attending it will be like making a strategic investment if your aim is to innovate, become more competitive or seek partnerships focused on growth in this sector.