Kazan Aviation Plant (KAZ, part of the United Aircraft Corporation of Rostec) is switching to continuous assembly of the Tu-214 aircraft fuselage. Instead of fixture technology, the company is introducing a conveyor-based production principle. "Perviy Technicheskiy" in its article explains why fixtures in aircraft production are a thing of the past.
Why Fixture Assembly Slowed Down Aircraft Production at KAZ
First, we need to understand the terminology. Fixture technology has remained the basis of aircraft construction in Russia for decades. The fuselage was assembled on stationary structures, where each operation was performed manually and sequentially.
This approach ensured accuracy but sharply reduced production rates, since one body could remain on the fixture for months. Any delay in one area blocked the work of the entire line. Reconfiguring equipment took weeks, so scaling up production with this scheme is almost impossible.
As a result, the plant produced a limited number of aircraft even with orders and significant funding.
How Continuous Assembly Works
Continuous technology is based on the conveyor principle. The fuselage passes through several sections, where each team performs a strictly defined set of operations.
Each stage has uniform standards, digital control, and synchronized component deliveries. Work proceeds in parallel, without downtime or overlap. You can even draw an analogy with car production.
The new line will allow the Tu-214 fuselage to be assembled in 12 days. This is several times faster than the previous scheme. The project is being implemented with the support of the Agency for the Development of Professional Skills and the Center of Competencies in the Field of Labor Productivity.
What the Transition to Continuous Production Means for the Aviation Industry
Switching to continuous assembly instead of fixtures significantly changes the economics of production. The plant gets predictable deadlines, stable staffing, and reduced costs.
Increasing production to 20 "Tu" aircraft per year allows meeting the needs of airlines without constant supply disruptions.
Why This Is Called a Production Revolution
Abandoning fixtures means moving from one-off assembly to mass production. For Russian aviation, this is a key technological shift in recent decades.
The continuous scheme requires new competencies, digital management systems, and high supply discipline. If successfully implemented, the Kazan Aviation Plant will become a base platform for the large-scale production of domestic aircraft.