US FAL creation
& ramp-up plan
Context & objectives
Turboprop aircraft manufacturer wanted to jointly increase its production capacity and to mitigate potential tariffs increase by creating a new FAL in US
- To scale up production capacity
- While hedging against the potential impact of rising tariff exposure
Aim of the mission was to frame the new FAL
- Industrial content : FAL, aerostructure, detailed partss
- Optimization : Optimize footprint and FAL lay-out
- Logistic : Desing supply & logistics scheme
- Planification : Setup E2E integrated planning from building construction up to target rate establishment
- Ramp-up : Build ramp-up plan
- Finance : Estimate NRC and RC for the future FAL
The initial framing was expected in 3 months to obtain Company board validation
Résultats
Capacity analysis performed on the E2E industrial flow including aerostructure to support ramp-up
- Bottlenecks identified
- Investments plan to support ramp-up
Integral FAL lay-out design
- Assembly stations incl. pre-assy zones feeding stations
- Flight tests zones
- Specific tests areas (gauging, engine tests, …)
- Stock and logistics area
Operations design to reach “Zero Missing parts”
- MCA industrial planning
- Supply & kitting approach
- Logistics approach at P/N level
Investments quantification in US and France
Import duty simulation & mitigation plan
Board validation and FAL civil work start
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