Visit to Airbus in Hamburg

A fascinating yet challenging branch of model building is the construction of commercial aircraft replicas. Ambitious model builders often draw inspiration from the large aircraft produced by Boeing or Airbus. Through years of meticulous work, true aviation gems are created in many model workshops. However, it’s quite rare for modelers to have the chance to gain insight into the manufacturing of a real airliner. During my stay in Hamburg, I took the opportunity to get a glimpse into the Airbus production facility in Finkenwerder.

Airbus in Finkenwerder is a small town in its own right, where factory tours are offered regularly. Under expert guidance, the 2½-hour tour takes you across the vast factory grounds and through the impressive assembly halls. On the grounds of “Hamburger Flugzeugbau”—founded in 1936 for the construction of seaplanes—there are now three production lines for the final assembly of the Airbus A318, A319, A320, and A321 models. In addition, the Hamburg facility handles the complete cabin outfitting and painting, as well as final inspection and delivery of the A380, in a hall built specifically for this purpose.

In any modern manufacturing operation, it is essential that the required parts and assemblies be available “just in time” on the production line. In the case of Airbus, this process is particularly impressive, as the individual components are manufactured at various Airbus production sites and transported from there by truck, ship, and the distinctive Beluga transport aircraft to the

transported to final assembly facilities. The cockpit sections and the forward fuselage are built in France. The elevators are manufactured in Spain, and the wings are delivered from England. The rudders come from Stade, Germany, and various fuselage sections are manufactured in Hamburg. In the structural assembly facility for the A320 family in Hamburg, a rough-built structure of the individual fuselage sections is first created. This rough-built structure is then moved step by step through the

workstations until it reaches final assembly. As a visitor, you can experience firsthand how these giant aircraft are built.

Since, at Airbus, virtually no two fuselages are alike due to numerous production variants and varying customer requirements, the phrase “airplanes on an assembly line” may sound a bit strange to some visitors. In Hall 8 of the Airbus facilities in Hamburg, however, this type of production is a reality. In the past, work teams had to move their tools and materials to the fuselages; with the moving-line principle, the fuselage sections now move to the individual assembly teams. The individual components move clockwise through the assembly hall at a speed of one meter per hour until the control, propulsion, and passenger systems are fully installed. The teams’ workstations remain in place throughout this process, which significantly simplifies the flow of materials and production. After the wings and engines are installed, the airworthy aircraft is rolled out. It is then thoroughly tested and inspected by experienced Airbus test pilots over the North Sea under a provisional aircraft registration. All of this comes together

integrates seemingly seamlessly into the entire production process, so that one finished aircraft leaves the plant in Hamburg every day.

After the multi-layer final coat has been applied and the customer has approved the aircraft, the Airbus A320 family—which costs up to $100 million in its standard version—takes to the skies without delay. “Time is money”—this is especially true for airlines facing intense competitive pressure. It is not uncommon for the first commercial passenger flights to depart from an international airport on the very day the new aircraft is delivered. Without a fully functional and reliable logistics, manufacturing, and quality assurance system, this would not be possible.

On the Airbus factory tour in Hamburg, you get to experience modern aircraft manufacturing up close and personal. And if, like me, you’re an aviation fan lucky enough to have a long-time, former, and knowledgeable Airbus employee as your tour guide, the 14-euro tour becomes an interesting and exciting experience for any aviation enthusiast. Factory tours at Airbus in Hamburg-Finkenwerder are offered exclusively by the tour operator globe-tours.de. Please note that due to high demand and Airbus security regulations, you should book a few weeks in advance.

*Reto Minelli*