Case study Schiphol

For one of our long-standing clients at Schiphol Airport, we have significantly improved maintenance efficiency. Where previously multiple large scaffolds were required for replacing cockpit windows, there is now a single, innovative, universal solution.

The challenge: space constraints and inefficiency

The client, responsible for the maintenance of various aircraft types, encountered practical issues during cockpit window replacements. The situation was as follows:

• Duplicate equipment: Two different docks were required for two different aircraft types.
• Footprint: The existing docks were very large, occupying valuable hangar space.
• Mobility: Maneuvering the docks was heavy and cumbersome.

The objective was clear: develop one universal product that saves both time and space. The new dock had to fit the current fleet while remaining future-proof for upcoming aircraft types. Furthermore, the entire unit needed to be easily transportable.

The solution: a winning design

The client provided their own specifications and requested quotes from several parties. Why did they choose us? Because we looked beyond the technical specs alone.

In our design, we focused not only on the universal fit but also emphasized ergonomics and working conditions (HSE). The result is a dock that is safe and pleasant for technicians to use, and compact enough to move smoothly through the hangar. This thoughtful design was the deciding factor.

The process: from sketch to Schiphol

To ensure a perfect end result, we utilized a strictly phased project plan:

1. Engineering & Design: Following an initial rough sketch and a Q&A regarding specifications, we prepared a drawing and cost estimate. Upon approval, a detailed 3D model was created for Blueprint Acceptance.
2. Production & Coordination: During construction, regular detail consultations took place. Where necessary, we implemented minor specification adjustments immediately.
3. Factory Acceptance Test (FAT): The dock was fully tested in our workshop against the required specifications. After minor fine-tuning, the product was ready.
4. Logistics & Installation: We arranged specialized transport to deliver the custom dock to Schiphol, where it was assembled on-site.
5. Implementation: A Site Acceptance Test (SAT) followed, and users received comprehensive instructions on how to operate the equipment safely and efficiently. Additionally, maintenance training was provided so the client can perform first-line maintenance themselves.
6. Final Acceptance: One month after implementation, a final acceptance test takes place to guarantee that everything functions according to plan in practice.

The result

The client is highly satisfied with the solution. The key benefits include:

• Space savings: One dock instead of two
• Time efficiency: The dock is quick to move and set up
• Future-proof: Suitable for both current and new aircraft types
• Ergonomic: Improved working conditions for technicians