JUNE 2025AEROSPACEDEFENSEREVIEW.COM9From within the aerospace industry, there is a strong desire to improve: for years, organizations have been working to lay out their visions to achieve "zero defects." To clarify, this is quite different from safety, which is typically designed into system architecture (duplex, triplex, and even quadruplex are common) or system testing, such as simulated flight hours for pilots. The idea of "zero manufacturing defects" might seem like an impossible task, but with the use of AI, it could be more achievable than ever. While it is unlikely that AI will eliminate all unexpected problems, for the problems that remain, an AI assistant will be available to help evaluate large amounts of data or to help determine a root cause, even with sparse or disparate data. This will help identify and/or solve challenging production problems earlier, reducing time and cost while improving outcomes on the road to "zero defects."Finally, the driving force for the accelerated AI timescale is the workers using it. As AI continues to advance, new workers are going to expect it to be integrated into their work, training, and process improvement. When joining a new industry, wouldn't you take help to keep up with your more experienced and knowledgeable colleagues in order to contribute? Additionally, for "dyed in the wool" veterans of many aerospace programs, adoption will have a different complexion. This group is likely to be happy to have fewer mundane tasks that they can hand off to AI. It will need to be intuitive and clearly better than existing tools; otherwise, the need for change will not be felt. Another benefit that this group is likely to experience is new abilities that they would not have without AI. In the same way that new members of the workforce will be able to get up to speed faster, more experienced folk will also be able to change roles more easily, taking the soft skills that they have developed over many years of work.So, if all that I have described is realistic, why is the operator still featured in this scenario? There are several solid reasons. First, AI has an error rate associated with its output, probably between 40% for a task that it has been trained for but does badly and 1% for a task that it does really well. For decisions where getting it right matters, such as manufacturing high-quality aerospace products and solutions, a human operator will have to remain "in the loop" for the foreseeable future. Secondly, AI has no "intention," meaning that it doesn't want to do/be anything and has no hopes or dreams. At its root, AI is simply complex math that processes inputs to produce an output. (AI might be better named Applied Statistics: less dramatic but closer to the reality of what is happening.) In short, AI is a "power tool" and needs an operator to direct it.So, my beliefs have changed, and in a shortish period of time, I expect to see "An inexperienced operator walk up to a machine tool and, working together with AI, has a productive shift making important aerospace components." FROM WITHIN THE AEROSPACE INDUSTRY, THERE IS A STRONG DESIRE TO IMPROVE: FOR YEARS, ORGANIZATIONS HAVE BEEN WORKING TO LAY OUT THEIR VISIONS TO ACHIEVE "ZERO DEFECTS"
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