But before these components reach the FAL, they must be manufactured. Some are produced in-house by Airbus, others by third parties, and their production involves dozens of factories and centers around the world. Then there is the formidable logistical challenge of bringing them together. This complex ballet involves transport by boat, train, road and air, with a small fleet of special transport aircraft – known as Belugas – playing a key role. These planes, with their huge girth that makes them look like beluga whales, were created by Airbus to move large components such as fuselages from one production center to another.
The Airbus A321neo has just under half a million parts, from its seven fuselage sections to the rivets used to attach its surfaces, making it one of the most complex puzzles ever created. In addition to being assembled, all components must be inspected, tested and recorded in the logbook, which never leaves the aircraft. It catalogs the history and traceability of all its components.
Almost completed A320neo on the Airbus line in Hamburg.Photo: Antonio Dini
More than half of the A320s produced by Airbus are assembled here in Hamburg, where more than 30 aircraft are produced per month. There are several production lines running in parallel on different aircraft, but the most innovative part of the operation here is in hall 245. Since it began operations in 2018, this hall has been one of the most advanced production environments in the global aviation industry. Two giant robots that move along seven axes drill holes in the fuselage, while a series of mobile tool platforms move around the aircraft to complete other assembly elements, their positions controlled by a laser-guided automated positioning system. Together, these automated machines speed up production – a huge benefit given the demand for the A320 family of aircraft.
The popularity of these planes exploded. The well-documented problems with Boeing’s rival plane, the 737 Max, have worked in Airbus’ favor. The company is also working to develop increasingly fuel-efficient aircraft with the potential for lower operating costs, which are proving attractive to operators. Airbus says the A321neo can fly with 30 percent less fuel per passenger per kilometer than previous generations of competing aircraft.
Finally, there is the evolution of the air transport sector. The era of large, expensive and inefficient wide-body aircraft is waning and instead there is a growing demand for narrow-body aircraft with a single center aisle and more flexible characteristics. Aircraft such as those in the A320 family can land and take off from smaller airports, an important opportunity for low-cost airlines with their point-to-point flying patterns. These aircraft are also constantly increasing their capacity and the distances they can cover.
