The role of the manual drill in the aerospace manufacturing industry

A modern aircraft is riddled with holes. In a single aisle aluminum commercial aircraft alone, there are approximately 3 million holes and approximately 750,000 of those holes are drilled manually. Even in the era of automation, manual drills play a significant role in the aerospace manufacturing industry, accounting for roughly 25% of all holes drilled. Semi-automated drills account for 45% and fully automated drills stand for the remaining 30%.

Manual drills provide unprecedented flexibility, precision, and reliability. Characteristics needed for specific drilling tasks when manufacturing an aircraft. But with manual drilling operations follows the risk of potential human induced errors. That’s where ergonomics enters the equation.

The performance of a manual drill is all about the tool and the interaction between the tool and the operator. A simple trigger, lever, or button is used to activate the drill's motor. This can be powered by either electricity or pneumatic pressure. These reliable power sources ensure a consistent and uninterruptable performance.

Once the motor is engaged, it generates a rotary motion, allowing the drill bit to penetrate the material. By adjusting the speed and torque settings, facilitated by the drill's gearbox, the drilling process can be tailored to match the specific application requirements. This level of control empowers the operator to achieve precise results, achieving the highest levels of quality.

Manually operated drilling tools offer the best result when designed with the operator in focus. Human errors in manual drilling are predominately caused by incorrect training and operator fatigue. Based on aerospace employees’ self-reported average “bad hole” rate it is estimated that approximately 50% of oversized holes can be avoided if the operator has the right training and the right tool for the job.

Adequate and relevant training enable operators to determine whether production issues result from tool-related problems or issues with parts used in the assembly. Having well-trained operators, line engineers, and quality assurance representatives helps significantly improve productivity and quality.

The issue of operator fatigue is addressed by ensuring that operators have the right operator friendly drilling tools available. Drilling tool ergonomics is defined by their weight, size, handle design and sound levels. Ergonomically designed drilling tools enable operators to be more mobile, accurate, productive, and above all, safer.

In addition, drilling tools equipped with intelligent features that provide the operator with continuous operational feedback drive improved control and quality throughout the manual drilling process. Advantages that further reduce the number of errors, delays, and risk of oversized holes.