Context and Challenges

The aviation industry is undergoing a major transformation to maintain its competitive edge while adapting to the growing demands for sustainability and digitalisation. Despite significant technological advances, many processes within the Ground System Test (GST) station of the aircraft Final Assembly Line (FAL) remain manual and inefficient.

DILECO addressed this challenge by promoting a high level of digitalisation and the integration of PLM tools to optimise ground testing processes, reduce their environmental impact, and strengthen the competitiveness of the aerospace sector.

Our Approach

The project's overall objective was to develop and deploy PLM tools for aircraft ground functional testing based on eco-design principles. The proposed solution aimed to improve both the sustainability of the Final Assembly Line and the efficiency of the testing process from start to finish.

The project focused on implementing advanced technologies within the assembly line while integrating established manufacturing approaches such as the Moving Assembly Line (MAL), visual management systems, and just-in-time delivery systems to optimise both production and testing processes.

Key Objectives

• Develop and deploy PLM tools for ground functional testing.
• Improve the sustainability of the Final Assembly Line through eco-design principles.
• Increase the efficiency of ground system testing processes.
• Reduce the low level of automation in testing operations.
• Strengthen the competitiveness of the aviation industry.

The Solution 

The proposed solution centred on implementing advanced technologies within the Final Assembly Line to optimise both production and testing procedures. The project integrated:

• More efficient assembly procedures.
• Commercially available technologies.
• Visual management systems.
• Just-in-time delivery systems.

These tools and methodologies, developed in accordance with eco-design principles, were integrated to digitalise and enhance ground system testing processes, contributing to a more efficient and sustainable manufacturing environment.

Benefits

• Reduced production costs: Automation across aircraft assembly lines lowers manufacturing costs while delivering a rapid return on investment.
• Improved quality and reliability: Digitalisation ensures products are consistently manufactured to the same specifications, reducing the need for repairs and improving overall consistency.
• Enhanced competitiveness: Shorter production lead times and lower manufacturing costs enable companies to offer greater value while remaining highly competitive.
• Greater sustainability: The integration of eco-design principles and digitalised processes contributes to a more environmentally responsible manufacturing approach.
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The DILECO project, with a budget of 214.412,50 €, was carried out between 2018 and 2020 with 100% grant funding. It was funded by the European Commission under the H2020-CS2-CFP06-2017-01 call. Skylife Engineering acted as the project coordinator of the consortium, which had a total budget of 399.912,50 €.

At Skylife Engineering, we lead projects through our extensive expertise in the integration of advanced technologies and our strong commitment to sustainability in aviation. We work closely with every project manager, following a rigorous process of continuous review and improvement. This approach ensures the delivery of high-quality, safe, and effective solutions that create a real and lasting impact across the industry.