An aircraft engine manufacturer needed to ensure precision in their shroud assembly process, which involved 68 distinct steps. Each step required specific conditions, tool placements, and precise sequencing to maintain quality standards in engine component assembly.
The shroud assembly process involved multiple critical operations, including peels, flips, and stacks across different ply types. 70% of the steps contain similar motions and characteristics, which is challenging to differentiate without proper context. The manufacturer needed a solution to understand the complexity of the process and sequence to ensure that steps were completed properly for critical engine components.
Assembly Copilot uses AI, computer vision and advanced algorithms to guide and verify the complex assembly process. The system was implemented with optimized camera angles and enhanced contrast settings for clearer object detection. It could track interactions (e.g., hand-object, object-object) and also key hand postures.
The implementation included progressive model training over multiple iterations, growing from 1000 to 6300 images to ensure robust coverage of all assembly steps. The system defined clear verification criteria for each step: step triggers and conditions, required pre-step completions, actions that should be avoided, required objects in the work region, and objects that must be absent from the work region. This structured approach ensured every step was performed correctly and in proper sequence, maintaining quality throughout the complex assembly process.
Assembly Copilot successfully guided operators through the 68-step process by tracking each operation’s sequence and requirements. Camera angle optimizations provided clearer object detection through zoomed work region views and enhanced contrast settings. These improvements and flexible viewing angles enabled workers to maintain consistent quality across different layouts.
A leading aircraft engine supplier focuses on precision manufacturing in complex component assembly.
Aircraft Engine Manufacturing
Optimize complex shroud assembly through automated step verification and process guidance.
Brandin and his team help our customers with setting up the Pathfinder platform and getting up-to-speed on all the features and functionalities, in addition to assisting them with standardizing their processes where needed.
Brandin is a seasoned manufacturing leader, who has spent more than a decade designing and setting up assembly lines in both the US and China, optimizing them, and working with human operators to maximize productivity and quality.
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Andrey co-founded and successfully exited a startup to immigrate to the US. He spent his next eight years building the core data science infrastructure for Amazon’s supply chain planning team, and the CV/ML infrastructure for Microsoft’s HoloLens organization.
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Zeeshan was a scientific leader at Microsoft’s HoloLens division, where he invented AI technologies to assist frontline workers across industries. Earlier, he shipped IoT platforms and visual defect detection software for manufacturers at Siemens and MVTec GmbH.
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Huy led teams of scientists and engineers at NEC and invented technologies for driver assistance systems that are part of 500,000+ Honda cars. He is an inventor on more than 20 US patents, and his research papers are cited by every lab from MIT, Stanford, and CMU to Apple, Google, and Baidu.
