Our client, a leading aircraft maintenance and modification provider based in mainland Europe, specialises in refurbishment, upgrades, and maintenance services for private and publicly owned aircraft.
Background
The client manages a broad range of aircraft projects, from routine maintenance to advanced modifications. Their services include refurbishment, upgrades, and custom modifications, ensuring that each aircraft maintains optimal performance and meets all regulatory standards.
Challenge
Engineering challenges and contract variations are frequent occurrences for our client. The ability to respond swiftly and flexibly is critical for maintaining their reputation for delivering high customer satisfaction standards.
In this instance, a VIP customer requested a split scimitar winglet modification as a contract variation during a scheduled C Check on their Boeing Business Jet. This request posed several unique challenges:
- Timing and Location: The aircraft was already in the hangar undergoing extensive inspections and structural work, which limited available space and imposed strict safety protocols.
- Coordination: The aircraft’s structural integrity was partially compromised due to the ongoing maintenance work, requiring careful coordination to avoid interference with other engineering activities.
- Contractual Constraints: The modification needed to be executed within a tightly defined timeframe. Any delay could result in financial penalties and impact the overall project timeline.
Solution
To meet the project’s unique requirements, we quickly mobilised a dedicated team of six specialist engineers led by our Chief Engineer. Working closely with the client’s Project Manager, we defined a detailed project brief and work breakdown structure.
We collaborated closely with the aircraft’s original equipment manufacturer (OEM) and the winglet manufacturer to ensure accurate specifications, technical drawings, and instructions. This allowed us to procure all necessary components in time to meet the project’s tight schedule.
Given the restricted space and the presence of other teams working simultaneously, we maintained constant communication with all stakeholders. Daily stand-ups and progress meetings were conducted to ensure alignment and swift problem resolution.
Despite the logistical complexities, our team executed the winglet modification in situ, adhering to the highest safety and quality standards. This required precise planning and coordination to minimise downtime and maximise productivity.
Outcome
Although we initially planned for a nine-day installation window, our team completed the project in just seven days. By completing the modification ahead of schedule, we avoided potential financial penalties and additional costs associated with extending the project timeline.
The aircraft was handed back to the owner on time, with all additional works completed. This not only exceeded the customer’s expectations but also provided immediate fuel savings due to the aerodynamic benefits of the new winglets.
Conclusion
Our ability to rapidly respond and execute complex modifications, even under challenging conditions, reinforces our value as an embedded and trusted partner for our client. Over the past 15+ years, we have consistently supported the client through numerous engineering challenges, contributing to their ongoing success and reputation for excellence in aircraft maintenance and modification.
This case exemplifies our commitment to providing innovative, high-quality solutions that meet the evolving needs of our clients and their customers.