工業 4.0 是什麼？
趨勢一：人形機器人進入飛機產線
- 自主換電池，可 24 小時不間斷運作
- 靈巧雙手與觸感感測系統，能在狹窄環境中做精細操作
- 已在工業環境進行初步部署（如 BYD、Foxconn）
趨勢二：機器人變小，產能才能拉上來
趨勢三：檢查全面自動化，8 小時的工作變 20 分鐘
- Donecle 無人機：自動繞飛機掃描，只要 20 分鐘就完成全機檢測，並拍攝高解析影像，大幅降低高空作業風險。
- Air-Cobot 協作機器人：在地面自主移動，檢查艙門、輪胎等細部，替人完成重複性巡檢。
趨勢四：AR 讓維修人員「直接看見數位孿生」
趨勢五：人本生產系統，不只是「機器人取代人」
- 角色轉型：鑽孔工人變成機器人管理員，負責處理異常和系統優化，把人力放在更高價值的工作上。
- 輔助科技：外骨骼與智慧眼鏡降低身體負擔，讓資深技術人員經驗得以長期發揮。
- 設計即考慮製造：透過 DDMS（數位設計與製造系統），飛機設計階段就考慮機器人可製造性，落實 DfMA（為製造與裝配而設計）的概念。
How Airbus Uses Industry 4.0 to Build Airplanes?
Airbus says that the aviation supply chain is very complex, and with a global shortage of skilled workers, traditional human-based manufacturing has reached its limit. In this situation, Industry 4.0 is not just a cost-saving tool, it is a key strategy to overcome production bottlenecks and keep the industry running. Here are five ways Airbus applies Industry 4.0 in airplane manufacturing:
What is Industry 4.0?
Industry 4.0 means smart manufacturing. Instead of just following fixed steps, factories connect machines, systems, and people through data. This allows them to sense, analyze, and respond in real time.
It combines the Internet of Things (IoT), cloud computing, digital twins, and automation. AI is the core driver, turning large amounts of real-time data into decisions, like predicting equipment failures, optimizing schedules, assisting quality checks, or supporting human-robot collaboration.
In short, Industry 4.0 provides data and connections, while AI gives factories thinking and learning capabilities. Together, they make smart manufacturing a reality.
Trend 1: Humanoid Robots on the Production Line
Airplane factories were built for humans, so traditional industrial robots can’t easily work there. Airbus introduced UBTech’s Walker S2 humanoid robot, which can work alongside humans in existing spaces without major changes to the production line. This is a major milestone in aviation manufacturing.
Walker S2 advantages:
-
Can change its own battery and operate 24/7
-
Flexible hands with touch sensors to handle precise tasks in tight spaces
-
Already tested in industrial factories like BYD and Foxconn
This is still in the concept testing stage. Whether Airbus will switch to other robots, like Tesla’s Optimus, is yet to be seen.
Trend 2: Smaller Robots to Boost Production
Drilling in airplane assembly is not just punching holes, it directly affects the airplane’s structural life. Traditional drilling robots are too large for current pre-assembly lines.
Instead of rebuilding the production line, Airbus made robots fit the line. They developed the Medium-Sized Drilling Robot (MSDR), which is only one-third the size of a standard robot. It can work inside the fuselage, tail, and central wing-box lines, handling about 87% of drilling tasks.
Airbus also acquired MTM Robotics and Sobotech, bringing the Flextrack system in-house. Flextrack moves along the aircraft’s surface and ensures each hole is drilled perfectly vertical. By controlling design, integration, and maintenance itself, Airbus can increase production while maintaining top-quality standards.
Trend 3: Fully Automated Inspections – From 8 Hours to 20 Minutes
Inspecting an airplane’s exterior used to be very slow. For example, after a lightning strike, inspections required 5 technicians, lifts, and over 8 hours of high-risk work.
Now, Airbus combines automated inspection tools with the Skywise data platform, turning inspections into digital, trackable, and analyzable processes.
-
Donecle drones: Fly around the plane and complete a full scan in 20 minutes, capturing high-resolution images and reducing high-altitude risks.
-
Air-Cobot robots: Move on the ground to check doors, tires, and other parts, taking over repetitive inspection tasks.
All results are uploaded to Skywise, so cracks, lightning damage, and maintenance history can be tracked, compared, and even used to predict future problems. Inspections are no longer one-time checks; they become valuable, ongoing digital data that improve maintenance and flight safety.
Trend 4: AR Lets Technicians “See” the Digital Twin
Augmented Reality (AR) is now an essential tool on the production line. Airbus’s MiRA solution overlays digital twin models directly onto real aircraft.
-
Technicians inside an A380 can use a tablet to see 3D models perfectly aligned with real parts—like having X-ray vision.
-
Tests show inspection time is reduced by 80%, and errors drop by 40%.
AR is more than a support tool; it significantly reduces human errors and boosts efficiency.
Trend 5: Human-Centered Production – Not “Robots Replacing Humans”
Industry 4.0 is not about robots taking jobs. It is about human-centered smart production.
-
Role shift: Drilling workers become robot supervisors, handling exceptions and system optimization, focusing on higher-value work.
-
Assistive technology: Exoskeletons and smart glasses reduce physical strain, letting experienced technicians continue contributing their skills.
-
Design for manufacturing: Using DDMS (Digital Design & Manufacturing System), airplanes are designed for robot-friendly production from the start, implementing DfMA (Design for Manufacturing and Assembly).
In short, Industry 4.0 makes work safer, smarter, and more valuable for people.
The Future: Smart Factories Win the Competition
The aviation industry’s future depends not only on airplane performance, but also on how smart the factories are. Companies that can integrate data, AI, and robots will have the best chance to win the next decade of competition in the skies.
