How an Aerospace Plant Saved 40%+ on Workstations

Client: Safran Landing Systems — world leader in aircraft landing & braking systems · Sector: Aerospace manufacturing · Result: 40%+ saved on workstations and equipment

The challenge: doubling a plant without doubling its equipment bill

Safran Landing Systems — whose products touch more than 25,000 aircraft making over 40,000 landings a day — doubled the size of its Mirabel plant. The 5S-driven Lean Sigma team took the expansion as a chance to rethink workstations. The incumbent solution, large metal cabinets and drawers, was expensive, hid parts from newcomers, and couldn't adapt to changing processes.

The solution: a small trial, then an integrated in-house Flexpipe workshop

The team started with a small-scale trial of the modular tube and joint system. It worked, so they went further than most: they set up a permanent in-house Flexpipe workshop, stocked with components, so any department can request a structure and have it built on site within days.

• Shadow-boarded, open tool presentation replaced closed cabinets — parts visible at a glance
• Workstations rebuilt as processes change, with components reused each time
• An internal build service with rapid response to continuous-improvement requests

The results

• More than 40% saved on workstations and equipment versus the cabinet-based approach
• Faster onboarding — new staff find parts and tools without hunting through drawers
• Continuous improvement requests fulfilled in days, not procurement cycles

What this means for Australian industry

Aerospace and defence suppliers in Australia run the same 5S and AS9100-style disciplines. An internal modular-build capability turns every improvement idea into hardware within the week — without waiting on external fabricators or capital approvals for welded furniture. Flexpipe Australia can help you scope a starter component inventory for your own in-house workshop.