Aircraft assembly demands the highest possible quality standards. The procedures however are complex.The systems have complex configurations a nd are more and more tailored to each user in an environ-ment where design and training cycle times are also getting shorter and shorter.The high complexity of the procedures lead to errors, loss of time and increased costs. This results in loss of productivity and competitiveness.

By enabling tasks to be viewed in real time in the operational space, making them easy to understand, Augmented Reality facilitates improved understanding a well as faster and higher quality execution of procedures.This makes it possible to reduce error rates and save considerable amounts of time, energy and money.

For these reasons Diota has developed the Digital-Assisted Operations – a system specially designed for the requirements of the aerospace industry.

Case Study

Aircraft Sub-System Assembly

The SituationA large number of varied and changing tasks with complex paper-based instructions

To carry out these complex procedures, operators use paper manuals containing sub-assembly diagrams and textual procedure descriptions.

DifficultiesPaper-based manuals are heavy, bulky and unintuitive - even difficult to use. Even for the most experienced operators they are a source of difficulty and constraints throughout the operational process, particularly in relation to:

1.Identification 2. Understanding 3. Preparation 4. Execution 5. Cleaning> Before executionoperators are forcedto perform countingand marking tasks(with felt, chalk, piecesof cardboard) to ori-ent themselves on thesub-system.

> Correct perfor-mance of proceduresdepends on previoussteps (identification,understanding andpreparation of tasks).

> Understanding tasksto be performed;> Understanding theorder of execution oftasks.

> At the end ofthe procedurethe operator hasto clean-up hismarkings.

> Identification ofthe correct configu-ration.> Identification ofrelevant proce-dures.

Aircraft sub-system assembly procedures are based on tasks which can only be performed by human operators.A single procedure involves a large number and variety of tasks (boring, machin-ing, tapping, bevelling etc.) which vary from one configuration to another.

Enable operators to reduce errors1/ By facilitating understanding of tasks.2/ By ensuring procedures are performed reliably.

1/ By facilitating identification of systems and procedures.2/ By streamlining the operational process.

Reduce ErrorsOperations added, forgotten or confused due to:1/ Difficulty in understanding tasks.2/ Difficulty in performing them correctly.

Improve Productivity

Numerous Errors

Loss of Time1/ Time spent without producing value (looking for information, identifying procedures etc.).2/ Tasks without value added (marking, cleaning etc.).

ObjectivesConsequences

1 2 3

a b c

SolutionGuide the operator step by step with good instructions displayed in the right place at the right time

The Digital-Assisted Operations system consists of a pluridisciplinary Augmented Reality solution composed of the DiotaPlayer software platform and various hardware peripherals (ISAR projection system, glasses, tablet computer) which is directly connected to the PLM via the DiotaConnect gateway.

The operator can display clear, intuitive digital instructions in real time in the operational space and is guided through the assembly process step by step.

Production Engineering prepares work instructions in the PLM. These are then converted and exported directly via DiotaConnect in the form of an Augmented Reality project which can be used in the operational space

In the workshop the project is used by way of the Digital-Assisted Operations. The digital instructions guide the operator step by step, keeping his hands free for other tasks.

At the end of the procedure the operator can check the tasks have been performed correctly with a tablet com-puter. He can compare the as-designed on the digital mock-up with the as-built and identify any differences.

Following Step. When the tasks on the display have been performed the operator can move on to the next page on the instruction sheet when he is ready via the DiotaPlayer interface. He can then carry on with the next set of tasks.

Task Execution. The operator performs the tasks in the dis-play projected onto the sub-system. He can organise himself effectively and can perform tasks that involve the same tool or setting (e.g. boring of 4 mm holes) before changing the tool or setting (boring 6 mm holes).

Displaying Instructions. In the DiotaPlayer inter-face the operator selects the first page of the work instructions. He can then view the details from the display directly on the sub-system be-ing assembled using the ISAR projection system or head-mounted displays.

Documentation

Benefits

Advantages

No more looking for information: the operator has the right proce-dures for the configuration avail-able immediately.

No more difficulties in under-standing: digital instructions are intuitive, displayed in a universal language everyone can under-stand.

No more work errors: instruc-tions are displayed when and where they have to be performed.

No more tasks, actions and time wasted that do not add value.

Reduced Cycle Times Increased EfficiencyReduced error rates

> Instructions extracted directly from the PLM (no printing, distribution, recy-cling of paper manuals).> Work sheets fully aligned with the PLM and always up to date.

> Operators become independent: they can organise their work sequences and tool changes in an optimum way.> Operators can work calmly without making mistakes or needing to dou-ble-check anything.

Comfort and Independence

Monitoring and Traceability> A pdf report containing inspection reports, comments and operator pho-tos is generated automatically.

> Tasks can be viewed by oper-ators of all skill levels. > Collaboration is facilitated and the less experienced can quickly improve their skills.

Increased Skills

> Costs of errors eliminated.> Costs of time-wasted controlled.

Réduced Costs

Positive Factors

-90% -35% +100%

Dassault Aviation.

The system was accepted very well and the risk of making an error considerably reduced.

contact@diota.com+33 1 85 41 15 15

15 av. Emile Baudot 91300 Massy, France.

www.diota.com