Fokker Services recently installed a fully automated Twin Wire Electric Arc Spray in their LaGrange facility. Craig Winter, Managing Director at Fokker Services Americas speaks about the multiple advantages of this technology, the addition of more machines and grinding equipment complementing the Twin Arc, their expansion plans, the problem of a skilled workforce, and a lot more in an exclusive interview with Swati. k.
Q – Congratulations on the successful installation of fully automated Twin Wire Electric Arc Spray technology. Can you tell our readers about this latest technology?
Ans – Twin Wire Electric Arc Spray is one of several thermal spray technologies used to restore worn components. This fully automated technology, installed at our facility in LaGrange, USA, allows us to take control of the total restoration process in-house for hundreds of part numbers. Using a robotic arm, we can efficiently spray thick dense coatings of aluminum, steel, nickel, and various specialty alloys to restore various parts. In many applications, it is a suitable alternative to hexavalent chromium plating. Some of the main benefits of using this technology are that as we are streamlining our processes, we can pass on the time- and cost-saving benefits to our customers. As part of our ongoing environmental initiatives, the Twin Wire Electric Arc Spray eliminates the need for toxic chemicals used in chrome plating and uses a fraction of the energy to restore surfaces.
Q – Along with this technology, you have also made recent investments in additional machining and grinding equipment. Can you tell us about those investments and how does the additional machining complement the latest Twin Wire Electric Arc Spray technology?
Ans – Our strategy in making machine shop investments was twofold. First, our desire to vertically integrate the supply chain allows Fokker Services to maintain tight quality control, dramatically reduce turnaround times, and lower costs. Additionally, as an Engineer, I saw the value when our skilled Machinists and Engineers worked together. The strong working relationship that our team develops by collaborating every day has led to additional repair development opportunities and innovation.
Q – After the Arc Spray technology, what is the next component maintenance technology you plan to bring over to your facility?
Ans – We are always looking for ways to better serve our customers. Since we are always adding new component capabilities, we continue to look at repair and restoration processes, determine what the component needs, and explore how we can most efficiently restore those components to an overhauled level. In the coming months, we will focus on further strengthening our data, analytics, and visualization efforts. Supported by a skilled team of data scientists, data engineers, and Power BI specialists, we will boost our digitalization process to enhance customer experience, performance, and more.
Q – Restoring surfaces on a variety of hydraulic, pneumatic, flight control, and high-speed rotating components is a challenging idea, as these parts are mostly replaced with new parts or the repairs are outsourced. How does this technology benefit the customers?
Ans – The aircraft component maintenance business is driven by two market demands: efficiency and innovation. Our investments in technology fuel both. Our customers benefit from a quicker and more accountable turnaround time. This efficiency translates to better availability for our customers and more consistent deliveries. Our innovative repair development on cost-driving components can greatly reduce the cost of ownership through fewer new replacement parts, as well as fewer components becoming Beyond Economical Repair (BER).
Q – As Fokker Services’ focus is to modernize the facilities with the latest technologies, how do you tackle the challenge of training the team at these facilities?
Ans – Our people are the foundation of our organization. In a time when we see labor shortages in the news, we must ensure that our skilled technicians have the right expertise. We developed a comprehensive training program for our technicians which not only ensures they have the right skills to tackle different levels of repairs but also serves as a career development path for advancement and recognition. Technology is also woven into our training, building process consistency and reducing the opportunity for error.
Q – The aerospace industry is and will continue to face a severe shortage of skilled labor. Your views.
Ans – We recognized the potential for labor shortages in 2018-2019 and while COVID delayed growth in the industry, we now see skilled labor shortages emerging as a constraint. To address this, we are taking a more proactive approach. We are seeking new channels for potential employees to find us and creating development opportunities to retain our skilled colleagues. At Fokker Services Americas, we are collaborating with local universities and staffing partners, we developed pathways for transitioning military personnel, and we are working with state and local chamber of commerce to develop apprenticeship programs.
Q – Any expansion plans going ahead?
Ans – During MRO Americas, we were excited to announce the launch of our new Boeing 737NG nose-to-tail program. We are completing over 50% of the component MRO capabilities in-house for this program so we can maintain control over turnaround times, costs, and reliability. The program covers critical parts including IDGs, engine accessories, hydraulic actuators, cockpit controls, and instruments, so in the short term, our teams are focusing on further establishing this program with our suppliers for operators worldwide.
Read more interview… “Aircraft Maintenance Training is a part of our DNA”- Vallair
Q – Post-pandemic how is the current MRO demand from operators? With the holiday season and the lifting of restrictions, air travel is already picking pace across the world. How soon do you feel this will aid the MRO sector in the recovery from pandemic losses?
Ans – We see demand from operators increasing. However, different regions are recovering at different rates. Although we expect that full recovery to pre-pandemic levels will not happen for another year, which could be longer if unexpected developments occur, we have already begun our preparations for demand to return. Last year we invested not only in maintenance technology but also in our inventory to minimize supply chain issues where possible, particularly for components on the Boeing 737NG platform. Therefore, we are well-positioned to support operators, especially when it comes to CFM56 and LEAP engine accessories. Operators could experience delays in getting their units back from other shops if there are supply chain challenges, and if this is the case, our team is ready to step in and support with fast turnaround times.
