How 3D Metrology Solutions helped relocate a thrust inverter production line for Airbus

The Airbus A330neo, an upgraded variant of the A330, represents a significant advancement in aviation technology. This is largely down to its enhanced efficiency, aerodynamics and performance. A critical component of this aircraft is the thrust inverter. This aids in the deceleration of the aircraft during landing, by reversing the engine's thrust.

Airbus introduced strategic initiatives to optimise production processes and infrastructure. As part of this, they decided to relocate the production line of these thrust inverters to another building, within their manufacturing complex.

This case study explores how we supported Safran with this significant move. Read all about the objectives, planning, execution strategies, challenges and outcomes.

Project objectives

These were the goals of the project:

• Working with the logistical team to move a production line from one facility to another.
  

• Using a AT960 Leica laser tracker, measure all jigs in the old facility to see how exactly the jigs sat before anything was moved.
  

• Scan and measure the floor of the new facility and mark out where each jig would be sitting.
  

• Set each jig in the new facility to gravity, replicating the same position it was in at the old facility.

Client motivations

These were the main reasons for the move:

• Facility modernisation: The new building was equipped with state-of-the-art manufacturing technologies, providing a more advanced and efficient environment for production.
  
  

• Capacity expansion: The larger space allowed for potential future expansions, accommodating growing production demands.
  
  

• Process optimisation: The new facility's layout was designed to streamline production processes, reduce inefficiencies, and eliminate bottlenecks.
  
  

• Cost efficiency: Long-term cost savings were anticipated through reduced maintenance, improved energy efficiency, and optimised operational workflows.

Methodology

Pre-move preparation

The pre-move preparation phase was critical for ensuring a smooth transition with minimal disruption. Here are the steps we took:

• Pre-measurement of jigs in the old facility: Each jig was thoroughly measured in its original state in the old facility, prior to the move. This helped ensure that we could replicate the line once installed in the new facility. ERS pads were valued on the jigs to help us get them somewhere close, when first dropped into the new facility.
  
  

• Pre-measurement of new facility: In the new facility, the floor was scanned so we could mark out where every single jig would be roughly located. This helped us support the logistics team and save time when it came to setting the new position. To help us locate the new jigs, we installed ERS pads all over the new unit. This was so that we could book into the building and be ready to set straight away.
  
  

• Equipment disassembly: Specialised teams disassembled the jigs, paying close attention to labelling, documenting each part to facilitate reassembly.
  
  

• Packaging: Equipment was carefully packaged to prevent damage. Each package was labelled with detailed information about its contents and destination within the new facility.

The physical move

The physical relocation was executed with precision and careful coordination:

• Logistics coordination: Detailed logistics plans ensured timely, safe transportation of all equipment. This included securing appropriate transportation vehicles and handling equipment.
  
  

• Staggered move schedule: To minimise production downtime, the move was conducted in phases. Essential equipment was prioritised to ensure that critical production processes could be restarted quickly.
  
  

• Jig setting: Each jig was set as a pair, so that they were installed exactly as they were in the old facility. We remained fully informed on any problems at the old facility, so we could identify and correct any issues at the new site. Each jig was set to gravity, helping all Schunk pick-up point coordinates to be located correctly. We also confirmed that all rails were parallel, so there was no unnecessary stress put into the jigs.

Challenges and Solutions

Challenges included:

• Equipment downtime: There was a need to minimise the downtime of critical equipment to avoid significant production delays.
  

• Logistical complexity: It was critical to coordinate the safe and timely transportation of large sensitive jigs.
  

• Employee training: All employees would need to be up to speed and ready to support the process as soon as the jigs were lifted in.
  
  

The solutions we implemented were:

• Detailed planning: Comprehensive planning and scheduling minimised equipment downtime. Parallel processes and phased moves ensured that critical equipment was moved and reinstalled first.
  
  

• Specialised logistics: Experienced logistics providers were employed to handle the transportation of sensitive jigs. Detailed packaging and labelling minimised the risk of damage or loss.
  
  

• Employee training and orientation: Employees received thorough training on the new facility's layout and the new jigs. Morning briefs with the team helped ensure everyone was on the same page and working towards the same outcomes.

Project outcomes

Here’s what we achieved:

Operational efficiency

The move resulted in significant improvements in operational efficiency:

• Increased production capacity: The additional space and modern infrastructure allowed for increased production capacity, enabling the company to meet growing demand.
  
  

• Cost savings: The move resulted in long-term cost savings due to improved energy efficiency, reduced maintenance costs, and enhanced overall operational efficiency.

Quality and reliability

The new facility's advanced infrastructure contributed to maintaining high-quality standards:

• Consistent quality: Setting and verification of the jigs ensured that production quality remained consistent, meeting or exceeding previous standards.
  
  

• Enhanced reliability: The modern equipment and improved working conditions enhanced the reliability of the production process, reducing the likelihood of defects or failures.

Conclusion

The relocation of the production line for A330neo thrust inverters was a complex but highly successful project. Through meticulous planning, effective execution, and robust risk management, 3D Metrology Solutions helped Safran achieve its aims. The company therefore enhanced its production capabilities, improved operational efficiency, and maintained high standards of quality and reliability.

The move contributed to increased employee satisfaction and long-term cost savings, positioning the company for continued success in the competitive aerospace industry. This project demonstrated how strategic facility moves can drive significant operational improvements, supporting overall business objectives.