Aerospace Actuator Assembly Achieves AS9100 Certification
Precision assembly system for flight-critical components with full traceability
Project Overview
Aerospace manufacturing demands the highest levels of quality and traceability. When a leading Tier 1 aerospace supplier needed to scale production of flight-critical hydraulic actuators, they faced stringent requirements that made traditional manual assembly impractical.
Every fastener must be torqued to specification and documented. Every component must be verified as correct. And every step must be traceable for the life of the aircraft.
AS9100 Compliance by Design
The assembly system was designed from the ground up to meet AS9100D requirements:
Process Control
- Electronic work instructions guide operators through each step
- Torque tools automatically verify and document every fastener
- Interlocks prevent proceeding until each step is verified complete
Traceability
- Unique serial numbers scanned at each station
- All process data linked to individual assemblies
- Electronic records retained for product lifetime
FOD Prevention
- Enclosed work cells with controlled access
- Tool tethering and accountability
- Automated debris collection and verification
Precision Torque Assembly
The actuator assembly requires 47 fasteners with varying torque specifications. The system uses:
- DC Electric Tools: Precise, repeatable torque application
- Automatic Angle Monitoring: Verifies proper fastener seating
- Real-Time Documentation: Every installation captured and linked to serial number
Any out-of-spec condition immediately stops production and alerts supervision.
Customer Testimonial
"AMD Automation understood our AS9100 requirements and built a system that makes compliance automatic. We passed certification on the first attempt, and our customer audits have been flawless."
— Quality Director, Aerospace Tier 1 Supplier
01The Challenge
The client needed to scale production of flight-critical hydraulic actuators while meeting stringent AS9100 requirements and customer-specific quality mandates for traceability and process documentation.
- 100% traceability required for every component and process step
- Torque accuracy within ±2% for critical fasteners
- Foreign Object Debris (FOD) prevention mandatory
- Process validation required for every assembly operation
- Zero defect tolerance for flight-critical components
02Our Solution
AMD Automation designed a precision assembly cell with integrated torque monitoring, vision verification, and comprehensive data collection that meets aerospace quality requirements while improving throughput.
Precision Torque Assembly
DC electric torque tools with real-time monitoring and automatic documentation of every fastener installation.
Vision Verification System
Multi-camera inspection verifies component presence, orientation, and proper seating at each assembly step.
FOD Prevention Design
Enclosed work cells with positive pressure, tool tethering, and automated debris collection prevent contamination.
Digital Thread Integration
Complete electronic work instructions with operator authentication and real-time data capture for AS9100 compliance.
03The Results
The system achieved AS9100 certification on the first audit attempt and has maintained zero defect escapes through its first 18 months of production.
Technical Specifications
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