Northrop Grumman, a global aerospace and defense technology company, is revolutionizing the production of advanced aircraft with its Integrated Assembly Line (IAL). The IAL uses cutting-edge automation and robotics to produce precision F-35 subassemblies at unprecedented speed, quality, and affordability levels. In this newsletter, we'll explore how Northrop Grumman uses automation and robotics to improve the F-35 production process, how the company learns from automakers to develop an integrated manufacturing system, and what the future holds for advanced aircraft production.

Northrop Grumman's manufacturing experience is critical to its success in supporting the latest fighter aircraft. In late 2001, Northrop Grumman was named a principal member of a Lockheed Martin-led industry team to produce the stealthy, multi-role F-35 Lightning II’s center fuselage in significantly high volumes. This would require incorporating greater automation capabilities paired with cutting-edge robotics to ensure program success. Counting on automation to improve the F-35 production, Northrop Grumman had previously pioneered automated manufacturing systems to produce key subassemblies for military aircraft. However, the new expectation set was for a production interval of one day — a goal that would test even the most advanced aircraft assembly lines in the world.

To meet this challenge, the company turned to a comparable high-rate production industry in the country: the U. S. automotive industry.

Northrop Grumman teamed up with KUKA Systems North America, a Detroit-based automation technology company specializing in integrating assembly lines for the automotive industry.

The Integrated Assembly Line (IAL) represents the best production practices from both industries.

The U-shaped IAL is located at Northrop Grumman’s Aircraft Integration Center of Excellence in Palmdale, California.

It comprises over 100 build stations and 22 automated systems designed to enhance quality, safety, and affordability.

Now operating at full production, the IAL currently completes an F-35 center fuselage every 30 hours, corresponding to a production interval of 1.25 days.

To date, Northrop Grumman has delivered 850 F-35 center fuselages.

In 2021 alone, the company plans to deliver 149 such units.

One of the most remarkable aspects of the IAL is that it produces all three F-35 variants — Conventional Takeoff and Landing (CTOL), Carrier Variant (CV), and the Short Takeoff Vertical Landing (STOVL) — at the same time.

All three variants use the same base tooling.

The supply chain team helped develop a methodical process for delivering parts to the IAL using “shadow boxes.”

This makes multi-variant production a seamless endeavor on a single production line.

Northrop Grumman's Integrated Assembly Line is a prime example of how automation and robotics revolutionize the aerospace industry. By learning from automakers and developing an integrated manufacturing system, Northrop Grumman has improved the F-35 production process, enhanced quality, safety, and affordability, and delivered more units than ever. As the aerospace industry continues to evolve, it's clear that companies like Northrop Grumman will continue to use cutting-edge technologies to push the boundaries of what's possible.