Case study: how robotization enabled J&C Aero to double its production rates

Seat refurbishment is a complex process that not only requires the involvement of multiple specialists but, in many cases, also heavily relies on manual labor. The latter implies additional production challenges and severe limitations when it comes to expansion capacities. However, entrusting some of the seat refurbishment stages to automated cutting and nesting systems allows companies to significantly increase their production rates, shows a case study by J&C Aero.

Once aircraft seats are removed from an aircraft and delivered to the repair shop, they are disassembled with all covers, cushions, and other materials being removed from the seat structure. Then, the seats and any additional equipment, e.g., electronics and in-flight entertainment systems, are being overhauled and new cover materials are being produced in line with the new design requirements. 

“The whole process used to be practically handcrafted. Naturally, it limited our capacities to serve no more than a couple of narrow-body aircraft at a time. Any orders that required the refurbishment of more than 180 seats put a lot of pressure on TAT and our team,” explains J&C Aero’s Chief Operating Officer Vitalijus Malyška. “Thus we needed to re-engineer our internal production processes and introduce automated solutions that would allow the expansion of our capacities. Thanks to the support of EU funds, we were able to acquire new equipment that fundamentally changed our production.”  

The new equipment allows precise and prompt metal milling, as well as the cutting of composites and other materials required for cabin interior elements. In addition, thanks to the in-built CNC system, the equipment can be easily adjusted or upgraded to produce additional, non-standard components. 

“The best part is that the new equipment is universal and applicable in numerous areas. For instance, with its help, we can produce Braille placards that are mandatory in some countries thus allowing us to reach new customers. In terms of composite or leather cutting, it allowed us to reduce the process from several weeks to several days. It also helped us to scale the production of our Cargo Seat Bags. In terms of seat refurbishment, the robotization of several production stages allowed us to double our capacities which in turn became a solid ground to attract new major industry players as customers,” concluded the COO of J&C Aero. 

J&C Aero is an international aviation center for innovation in cabin transformation and CAMO. As an EASA-certified design, production, maintenance, and CAMO organization, J&C Aero provides extensive cabin interior and repair solutions for narrow and wide-body aircraft operators and owners.

The range of the company’s services covers cabin interior design and production, aircraft line and parts maintenance, engineering and continuing airworthiness management, aircraft teardown and spare parts supply, as well as special-purpose STC and VIP cabin solutions.

J&C Aero holds EASA Part 21J, Part 21G, Part 145, and CAMO approvals, supplemented by multiple STCs, authorizations, and other approvals.

More information: www.jcaero.com