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GKN Aerospace UK Site Reaches New Heights in Reliability and Efficiency with Lectra Solutions for Composites

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GKN Aerospace UK Site Reaches New Heights in Reliability and Efficiency with Lectra Solutions for Composites Success Story GKN Aerospace UK site reaches new heights in reliability and efficiency with Lectra solutions for composites THE CHALLENGE Reliably meet increasing demand while controlling cost and quality. LECTRA’S RESPONSE Lectra’s aerospace solutions increase productivity and reduce material waste for reliable, efficient, and high quality production. SOLUTIONS In an industry marked by increasingly strict quality regulations and impending deadlines for lowering environmental impact, GKN Aerospace truly soars. A leading tier one supplier of aircraft components across the globe, the company is proactively developing “Lean Manufacturing” technology for its clients while working to increase sustainability and efficiency in its own business. Lectra’s previous experience with GKN Aerospace’s business and processes, combined with its 20-year history as a leader in the aeronautics industry and its expertise in industrial best practices (stemming primarily from the auto industry), positioned Lectra as an ideal choice to work with the GKN Aerospace facility at Cowes on the Isle of Wight, UK, as it moves toward a goal of leaner technology and optimized production processes through a “Lean Manufacturing” program. THE CHALLENGE As composites have become an in-demand solution for better performance and lower emissions, GKN Aerospace at Cowes needed to meet increasing demand and control costs without compromising on quality. With some composite material cutting done “We get increased by hand and some using ultrasonic technology, the processes at GKN Aerospace’s reliability and greater Cowes site had been largely labor-intensive. To maintain pace with customer demand productivity with these while extending the application of lean initiatives, GKN Aerospace recognized the need to move towards advanced automated manufacturing processes and technology-led latest-generation design solutions. Vector cutters. The blade technology THE SOLUTION developments and As part of their “Lean Manufacturing” program aimed at increasing sustainability and increased flexibility are efficiency in all areas of the business - including reducing energy consumption, process helping us to achieve time, and material waste - GKN Aerospace - Cowes turned to Lectra to take advantage the fine tolerances of their expertise in the field, as well as their existing experience with GKN Aerospace, required by our having accompanied the firm in their strategy and growth over the past 15 years. Using customers as well Lectra’s state-of-the-art composite solutions, remarkable improvements have been as the increases in achieved, increasing productivity, quality, and efficiency while reducing costs. output.” MEETING DEMAND IN A FAST-MOVING INDUSTRY Peter Steen, Value Stream Manager The use of composite materials in aviation has increased to represent 50% of the Composite Logistics at total airframe content in the latest aircraft designs. Some estimates suggest a GKN Aerospace – Cowes further increase to as much as 80% for the next generation aircraft. Lectra has helped GKN Aerospace - Cowes keep up with increasing demand efficiently and cost- effectively.“Through ongoing investment in the development of our employees, our technologies, and our customer programs, we are well positioned to continue the strong growth achieved in recent years,” affirms Adrian Sayce, Operations Program Manager for Composites at GKN Aerospace – Cowes. Lectra has helped GKN Aerospace - Cowes efficiently meet changes in material types. Increasingly user-friendly Pilot Control Software dedicated to ply cutting allows faster changeover between jobs and simple fine-tuning of cutting parameters. Peter Steen, Value Stream Manager composite logistics at GKN Aerospace - Cowes, in charge of scheduling all composite materials across four departments, explains: “Having been in the business 37 years, I have witnessed clear improvement with the new generation cutters. Each machine has evolved remarkably with technology. Our newest solution, created with Lectra’s support, is faster, more user-friendly, adapted to our specific needs, quieter, and more economic in cutting.” Material savings are a real benefit for GKN Aerospace - Cowes, which currently has an annual budget of around £12 million for composites materials. “We use Lectra cutting machines for cutting single-stack woven materials and their marker-making for advanced nesting, which helps us lower material wastage,” says Peter Steen.“These solutions have met all our requirements for them.” PARTNERING FOR ONGOING SUCCESS Beyond technically advanced solutions, Lectra offers companies such as GKN Aerospace knowledge of the aerospace industry and understanding of changes in the industry - helping each customer adapt their optimization strategy and solutions to real-world challenges. A comprehensive maintenance training program complements Lectra’s remote service contracts. Delivered via a dedicated response center, Lectra’s service contract allows GKN Aerospace at Cowes to get immediate help without the need to wait for interventions by onsite technical engineer, so they can work faster and smarter. “GKN Aerospace - Cowes has worked with Lectra for 15 years, and we’ve always been satisfied with the service they offer. We see Lectra as an industry expert and value their advice,” concludes Sayce. About GKN Aerospace GKN Aerospace is a first tier supplier to the global aviation industry, working on every major fixed and rotary-wing platform. Leaders in composite and metallic technologies, they focus equally on military and civil markets. Substantial investments ensure GKN Aerospace is at the forefront of technology. Partnering with the world’s major technology companies and participating in programs such as the “Clean Sky” Joint Technology Initiative, GKN Aerospace delivers competitive advantage through advanced design and manufacturing - solidifying their position as a world leader in aerostructures and engine components. Part of this global aerospace group, GKN Aerospace - Cowes, is dedicated to composites materials, manufacturing large, complex wing, nacelle, primary, and secondary structures. With complete, certified engineering capabilities and modern manufacturing facilities and processes, GKN Aerospace – Cowes designs and delivers high performance structures to customers including Airbus, Boeing, and BAE Systems. ® DesignConcept, Diamino and Vector are registered trademarks of Lectra. trademarks registered are Diamino and Vector ® DesignConcept, About Lectra Lectra is the world leader in integrated technology solutions that automate, streamline, and accelerate product design, development, and manufacturing processes for industries using soft materials. Lectra develops the most advanced specialized software and cutting systems and provides associated services to a broad array of markets including fashion (apparel, accessories, footwear), automotive (car seats and interiors, airbags), and furniture, as well as a wide variety of other market sectors, such as aeronautical and marine industries, wind turbines, and personal protective equipment. Lectra serves 23,000 customers in more than 100 countries with 1,350 employees. The company is listed on NYSE Euronext. Visit us at lectra.com.
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