Case study

BAE Systems collaborates with Diota
to drive digital transformation on the
Eurofighter Typhoon production line

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Industry : Defense Aeronautics

BAE Systems provides some of the world’s most advanced, technology-led defence, aerospace and security solutions. They employ a skilled workforce of 89,600 people in more than 40 countries. Working with customers and local partners, they develop, engineer, manufacture, and support products and systems to deliver military capability, protect national security and people, and keep critical information and infrastructure secure.

ROI

  • Ergonomics
  • Efficiency
  • Quality improvement
  • Optimization of production line

Introduction

Connected to BAE Systems’ Intelligent Workstation System, Diota software is deployed through a wide range of technologies within the Typhoon production line at BAE Systems Samlesbury, UK facility. Augmented projection, tablets, Hololens 2 headsets and PCs are integrated together into the production environment to assist operators during complex assembly operations, thus combining efficiency and ergonomics.

Projet développé par Diota et Fairfield pour BAE Systems

Challenges

The challenge was to explore ways to use technologies in an interactive and intuitive way that would help operators working on complex tasks and in confined areas. 2D drawings and written instructions have been replaced with 3D animated instructions to show the operator what needs to happen in a process and the sequence it needs to happen in.

The collaborative approach that BAE Systems have driven can also be seen in the close working relationship that exists with specialist suppliers in a range of areas, from augmented reality to the development of Internet of Things enabled connectivity.

Working with other suppliers including Fairfield Control Systems, Diota has helped deliver solutions that make the Typhoon production line smarter, more accurate and efficient while ensuring the team’s ability to use innovative technologies on complex sub-assemblies with high added value.

Solution 

As part of the industry collaboration, Diota’s systems were integrated onto devices used by the operator including tablets, hololens and a projection system allowing subassembly workers to operate hands-free.

guiding operators in the assembly of complex products- operator 4.0 in the factory of the future
projection of drilling instructions

Integrated into an intelligent Industry 4.0 system and connected to the BAE Systems IT environment, the augmented projection technology allows information to be visualized directly on the component being assembled. The equipment is localized in real-time by the Diota solution so that the work information always appears in the right place. These instructions can be adapted to allow a perfect understanding of the operators: color code, drawings, images.

Based on the digital mock-up, the digital interactive work instructions are brought directly to the shopfloor and materialized via augmented reality. Operators are guided step by step through the assembly process and conformity checks during the manufacturing procedure, reducing the risk of errors. 

assist operators during complex assembly operations with hololens - operator 4.0 in the factory of the future
guiding operators in the assembly of complex products - operator 4.0 in the factory of the future

Results & Benefits

  • A projection system integrated into the workspace
  • Non-invasive and easy to use
  • Reduced risk of error 
  • Improved working environment, ergonomics 
  • Reducing the impact of learning curve for new team members
  • Optimization of quality
  • Increased efficiency
guiding operators in the assembly of complex products

It has been a pleasure working with DIOTA on these projects. Collaboration, pushing the boundaries in the way we work, and the operators embracing the technology has been key to the success of using these technologies here at BAE. The projection and AR capabilities have added great benefit for the operators, providing  them with a more efficient way of working. It was a challenge deploying these technologies during the pandemic, but Diota gave us confidence in their products with virtual meetings, demonstrations and assistance throughout.”

Neelofar Ansari, Senior Manufacturing Development Engineer, BAE Systems
digitalisation des lignes industriels

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