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An international aircraft manufacturer was struggling with fully utilized capacities in cabin production. The pre-assembly of the overhead bins in particular led to delays on the final assembly line. The complex assemblies made up of structural parts, mechanics, dampers, lighting elements and panels required precise work steps and seamless documentation - but neither personnel nor buffer capacities were available internally.
The overhead bins had to be pre-assembled to a consistently high quality so as not to slow down cabin production any further. At the same time, different components had to be reliably tested, mechanical components precisely aligned and the functionality of each unit ensured. It had to be possible to integrate an external solution at short notice without affecting the ongoing series production process.
The Zettl Group took on the complete pre-assembly of the overhead bins in its own assembly area. This included logistical processing, component testing, assembly of the load-bearing structure, integration of hinges and dampers and functional testing of the opening mechanism. All work steps were implemented in accordance with customer-specific requirements and digitally documented, ensuring consistent quality and complete traceability.
The pre-assembled overhead bins arrived at the customer ready for assembly and fully tested. This stabilized cycle times in final assembly, significantly reduced internal capacity bottlenecks and minimized rework. Cabin production gained planning security and the manufacturer benefited from a reliable, scalable solution for its component assembly.
Reduction of internal bottlenecks and noticeable relief for final assembly
Precise, digitally documented pre-assembly ensures consistently high quality
Up to 30 % lower reworking costs thanks to stable, tested assemblies
