Spirit AeroSystems to Enhance 737 Fuselage Production Process

Spirit AeroSystems, a prominent supplier to Boeing, has officially announced its strategy to integrate more sophisticated technology into the production process for the fuselage of the Boeing 737. This initiative is designed to enhance overall quality while addressing the ongoing difficulties associated with the manual-centric production process.

During the company’s 2023 earnings call on 6th February, Spirit’s chief executive, Patrick Shanahan, unveiled the upcoming phase of enhancements, which will entail the implementation of automation for sections of the aircraft that currently heavily rely on manual labour. Shanahan underscored the necessity of this step in achieving zero defects and zero escapes, in order to resolve the persistent quality issues that have impacted various programmes, including the 737 and 787 structures.

The company has faced recent challenges, such as the identification of incorrectly-drilled holes in the 737 fuselages supplied by Spirit, a recurring problem for the company over the past few years. Shanahan has conveyed confidence that the integration of automation will play a critical role in resolving these issues, emphasizing the substantial human-assisted technology at their disposal and their intent to expedite its deployment with the requisite resources and investments.

However, Shanahan also recognized the constraints imposed by the design of the 737, which was conceived around manual processes in the 1960s. As a result, the use of full-scale robotics is deemed impractical for the production of 737 fuselages. The company’s focus will primarily be on the forward and aft fuselage sections, both of which present complex physical geometries and confined workspaces. Shanahan emphasized the challenges faced by mechanics when working in these areas, likening the experience to that of a gymnast.

Alongside automation, Spirit AeroSystems is also emphasizing improved worker training and enhanced product testing to minimize human errors. Shanahan affirmed that the company is striving to strike the right balance between human-assisted technology and automation, underscoring the existence of a clear path towards deployment.

It is apparent that Spirit AeroSystems is expending deliberate efforts to advance the production process for the Boeing 737 fuselage, with the goal of seamlessly integrating manual processes with modern technology to ensure the highest levels of quality and efficiency. Despite the inherent challenges posed by the aging design of the 737, the company’s dedication to innovation and improvement remains steadfast.