The Commercial Aircraft Corporation of China (COMAC) has developed the single-aisle C919 commercial airliner to advance commercial aviation manufacturing capabilities within China and for use throughout the world.  COMAC’s desire with this new aircraft is to offer tremendous customer benefit in terms of both capital investment and operating costs as well as a more satisfying passenger experience, including a “safer, more comfortable, more economical and more eco-friendly” airliner. 

Initially, AIT was asked to participate in a study to design the complete C919 final assembly line.  After successful completion of the study, the technical specifications were rolled out for bidding, and AIT was ultimately selected to further develop the final assembly design and subsequent manufacture of the assembly line’s tools and equipment.  This final assembly line is now currently being used in production in COMAC’s manufacturing facility in the Pudong area of Shanghai, China.

The assembly line accommodates three different variants in airplane length while maintaining the airplane assembly process integrity.  Depending upon the version of airplane to be produced, the work cells can be easily reconfigurable to meet these flexibility challenges.

The C919 final assembly process comprises five major work stations.  Components from different manufacturers are brought into the factory from locations all over China and then assembled to create the C919 airplane.  Tools and equipment ranging from simple fixtures to complex alignment and positioner systems carry out these assembly tasks.  Ergonomics, space reduction, and lean manufacturing techniques are paramount and were implemented during the design process.  The first major commercial airplane from China is scheduled for 2015.

• Work platform to access the nose section from the inside cabin floor and also the factory floor level.  The platform incorporates retractable arms, flip doors, removable sections and access stairs to assist the operators.
• Transportation dolly for moving and supporting the airplane nose section
• Body fittings attached to the nose section for handling and locating

• Telehandlers
• Wing transportation dollies for supporting each of the wings
• Body fittings and support beams attached to the wings for handling and locating on the fixtures

• Rear fuselage transportation dolly
• Floor grid, crown panel, and keel panel installation strongbacks
• Panel manipulator-style alignment and positioner system to install the side panels, floor grid, crown panel, and keel panel
• Tower-style alignment and positioner system to align and join the rear fuselage, side panel sub-assembly, and AFT fuselage
• Body fittings and support bars attached to the fuselage sections for handling

• Work platform to access the entire length of the fuselage during assembly process, from the inside cabin floor and also the factory floor level
  The platform incorporates reconfigurable handrails, flip doors, drop-in panels, removable sections, and access stairs to assist the operators.
• FWD fuselage transportation dolly
• Tower-style alignment and positioner system to align and join the fuselage sections
• Body fittings attached to the airplane sections for handling

• Tower-style alignment and positioner system to  align and join the wings to the fuselage
• Work platform to access the horizontal tail and vertical fin assembly operations
  The platform was uniquely designed to be moveable on air bearings and serves as a base for five can-style positioners used to align and join the horizontal tail cone and stabilizers to the AFT fuselage.  The platform also incorporates flip doors, actuated platform sections, and access stairs to assist the operators.