This project was set out to revolutionize the air transport industry by empowering comprehencive access to all aircraft maintenance functions through superior accessibility options to perform all maintenance functions on the new A380 enabling safer and more efficient operations across all major maintenance functions.
What sets this project apart was our ability to combine innovative engineering with advanced automation, delivering a tailored solution that exceeded HMCAiC’s operational goals.
This project stands as a testament to our commitment to driving value through innovation, rigorous planning, and a deep understanding of our client’s needs.
| Client | HMCAiC |
| Project Type | Industrial Fit-Out and Systems Integration |
| Project Value | $8m |
| Project Dates | Jan 2010 – Sept 2010 |
| Strategic Objective: | To revolutionize aircraft maintenance accessibility by developing an innovative roof-supported, automated dock system, enabling safer and more efficient operations across all major maintenance functions. |
| The Challenge / Need: | HMCAiC faced significant challenges in meeting the accessibility and safety requirements for their aircraft maintenance processes. Key pain points included: • Limited accessibility to critical aircraft components for maintenance personnel, impacting efficiency and timelines. • Reliance on ground-based systems that were cumbersome, space-inefficient, and prone to operational delays. • The need to integrate advanced automation for the movement and positioning of maintenance docks, ensuring precision and collision avoidance. The solution needed to leverage the existing roof infrastructure while maintaining strict safety and operational standards. |
| Our Approach | We conducted a comprehensive analysis to design and deliver an innovative system tailored to HMCAiC’s specific requirements. Our approach included: • Business Needs Assessment: Engaged with stakeholders to identify pain points and operational goals. • Safety and Operational Integration Analysis: Ensured alignment with industry safety standards and seamless integration into existing operational workflows. • Executive Leadership Engagement: Developed a compelling business case and presented strategic recommendations to secure buy-in. • BIM Integration: Leveraged Building Information Modeling (BIM) for precise planning and documentation. • Automation Development: Designed an advanced system for automated dock movement with precision distance and speed controls, ensuring operational efficiency and safety. |
Solution & Key Deliverables | The project delivered a groundbreaking roof-supported maintenance dock system that included: • Two Wing Dock Systems: Positioned on the left and right of the aircraft for streamlined maintenance access. • Two Nose Dock Systems: Providing safe and efficient front aircraft access. • Two Tail Dock Systems: Enabling secure maintenance operations at the aircraft’s rear. • Automation Integration: Dock systems equipped with distance, speed control, and collision avoidance technology for optimal safety and precision. • Comprehensive Documentation: Full handover package referencing BIM and integration with the Digital Control Model (DCM). • Operational Training: Hands-on training for HMCAiC staff to ensure smooth adoption and long-term success. |
| Risks and Challenges | This techonology had been implemented on smaller hangers with smaller overall structural load profiles, smaller lighter and less operationally intensive features. Our challenge was to do more than simply ‘scale the idea 10x’ rather from first principals engineer the entire thesis of design, evaluate every feature and use case, to optimise the design, the features and assess failure modes to ensure that the ‘whole design’ acheived best in class of all use cases. |
| Result / Outcome | The project achieved transformative results for HMCAiC: • Full accessibility to all critical areas of the aircraft for all major maintenance functions. • Elimination of ground-based systems, optimizing floor space and operational efficiency. • Seamless integration of an automated, roof-supported dock system, enhancing safety and reducing maintenance timelines. • Empowered maintenance teams with tools and training to sustain long-term operational excellence. |
| Our Value-Added Differentiator: | What sets this project apart was our ability to combine innovative engineering with advanced automation, delivering a tailored solution that exceeded HMCAiC’s operational goals. By leveraging the existing roof infrastructure, we eliminated ground clutter, maximized space efficiency, and introduced a fully automated system that enhanced safety, precision, and productivity. This project stands as a testament to our commitment to driving value through innovation, rigorous planning, and a deep understanding of our client’s needs. |
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I led the development and execution of the project as Head Contractor Program Director/delivery team.
Design for the design project the team consisted of:
- 1 x Lead designer
- 8 x Engineers,
- 10 x Drafters
- 1 x PLC/SCADA designers
Construction for the Construction project the team will consist of:
- 1 x Project Manager
- 1 x Construction Engineer
- 1 x Contracts Manager
- 1 x Quality Manager
- 1 x Safety Manager
- 1 x Structural Fabrication contractors
- 1 x Mechanical systems Fabrication contractors
- 1 x Erection contractor
- 7 x Functional Suppliers (Motors, Gearboxes, Drives, Pullies, Idlers, P&I Monitoring/Control )
- 1 x Electrical contractor
- 1 x Construction Manager
Project was completed with 126,000 hrs with ZERO LTI and 1 x FAI.
