Next Generation Manufacturing - Assembly and Test

Based on the most advanced principles of lean manufacturing, the Mirabel Aerospace Centre features technologies and processes which result in increased efficiency. The facility will also house two of Canada’s largest aircraft engine test cells.

Other features and benefits include:

• Visual production: Giant screens throughout the facility will show production status.
• Just-in-time delivery of supplies: Key suppliers will be able to monitor production status and have supplies delivered in line with the pace of production.
• High level of automation: Automated torque monitoring, induction heating (use of electromagnetic elements for heat instead of ovens), robotic inspection, higher level of test cell automation, Automated Guided Vehicles (cars without drivers) to move parts, tools and engines, automated moving line.
• Paperless environment: Each workstation will have screens providing instructions to assembly employees. Parts from the supply base will arrive in returnable boxes to reduce the use of cardboard.
• Ergonomic workstations: Ergonomics were considered for each workstation. A roll mechanism allows the engine to turn while overhead so the assembler never has to climb above the engine or climb underneath it. This helps avoid potential ergonomics issues.
• Sterile zone: No food, drinks, personal electronics or jewelry will be allowed in this zone. Our benchmarking with the pharmaceutical industry has shown us that this can help ensure product integrity (e.g. avoid a scratch on an engine caused by a watch) and avoid loss of concentration (e.g. when a cell phone rings.)
• Clear, streamlined environment/flexible factory: No permanent toolboxes on the assembly line. The required tools are brought to the workstation before each step in the assembly process for increased flexibility.
• Continued improvement: Line stoppages can be planned to enable quality clinics and empower employees from a continuous improvement perspective.

Test cells:

The assembly and test facility will house two engine test cells. These will be Pratt & Whitney Canada’s largest test cells and amongst the biggest aircraft engine test cells in Canada -- able to test engines up to 35,000 pounds of thrust. The test cells are 92 metres long and up to 35 metres high.