Virtual validation shortens dry-run phase by 30 percent

How can challenges in manufacturing be overcome so as to boost operating efficiency? In our client project with Airbus Atlantic, we developed a cross-board strategy to achieve just that.

Following project kickoff, we conducted an in-depth review of legacy processes and identified weaknesses that had to be eliminated. The core issues proved to be production errors and cost-intensive dry runs. Additionally, there was no tool for precise virtual replication of real processes in robot programming and validation. Together with the client, we reviewed available software solutions with a view to their ability to satisfy the specific requirements of the Airbus Atlantic manufacturing environment.

The decision came to FASTSUITE Edition 2, a 3D simulation suite developed by CENIT. A clear argument in favor of this software was its ability to generate highly precise virtual reproductions of production facilities. Also, the application was able to streamline validation processes and improve overall production quality.

Primarily, FASTSUITE Edition 2 had been selected for virtual control validation. But Airbus Atlantic also plans to work with digital twin technology in future and therefore wanted to task the CENIT software with introducing digital twinning as well.

During implementation, we adapted FASTSUITE Edition 2 to Airbus Atlantic’s workflows and seamlessly integrated the solution with the deployed systems. We configured the simulation parameters and created digital twins of the production facilities. At all times, our team ensured full compatibility with the existing system infrastructure.

Drawing on the results of pilot tests, we fine-tuned the solution and iteratively optimized its performance. Following successful validation, Airbus Atlantic fully introduced FASTSUITE Edition 2 at its production sites. The solution was integrated with standard project procedures for the introduction of new machinery and production resources. Thus, all the benefits of virtual control validation and digital twinning are now available throughout the enterprise.

We conducted training courses to ensure that Airbus Atlantic’s users were sufficiently familiar with how FASTSUITE Edition 2 works. Our instructions covered all relevant tasks related to offline programming, virtual control validation and digital twinning. A key prerequisite of project success was the close collaboration between Airbus Atlantic, CENIT and all involved stakeholders.

Airbus Atlantic attained all its objectives: Greater operative excellence, higher product quality and development of innovative manufacturing processes.