Technical
services

The Energy Efficiency Plan has allowed us to identify and implement improvement actions focused on reducing the consumption of energy and containing carbon emissions. In this regard, the most important action has been to invest in photovoltaic installations on rooftops at the Boecillo (Valladolid) and Tres Cantos (Madrid) facilities.

Technical Services has led this project with an early analysis of the photovoltaic installation capacity on the roofs of each of the company's facilities, in order to establish the potential savings in consumption and emissions in each one of them and to progressively implement the installations. In September, the Boecillo (999 kWp installed capacity) and Tres Cantos (625 kWp) plants began generating their own electricity. In 2023, the next step will be to saturate the photovoltaic generation capacity of Boecillo, with an additional 250 kWp, and to implement the project that will enable the excess electricity not consumed at both plants to be fed into the grid.

The area has also continued to support the facilities upgrade and new capacity installation at different production centers.

The Energy Efficiency Plan has allowed us to identify and implement improvement actions focused on reducing the consumption of energy and containing carbon emissions.

Aerópolis has completed the office renewal, air conditioning upgrades, thermal insulation, electrical and data installations, and thermal recovery systems integration to optimize energy consumption.

Regarding the aeroengine business, the team has completed the commissioning of the eighth MCM iTank 1300 machining center at Ircio (Miranda de Ebro). Two new Hermle C62 machining centers have also been incorporated in the same facility, the first of which is already in operation and the second is being installed and scheduled for start-up in the first quarter of 2023. Likewise, shot blasting capacities have been boosted with the installation of new glass micro-spheres application equipment in a dedicated room, and the installation of the third Coordinate Measuring Machine (CMM) in the three-dimensional verification room of this facility has been completed.

The main actions in this area also include the installation of a Makino A61NX machining center at Orón (Miranda de Ebro) to handle the increased workload in previous contracts and the industrialization of new components.

In the aerostructures business, process improvement, safety, sustainability, automation and digitalization have been the main lines of action.

Since March, Tres Cantos has been using a new mixed pressurization system for the autoclave cycles, which provides a significant reduction in the N2 and O2 consumption, and a closed and pressurized area that mitigates the risk due to the presence of carbon fiber in the surroundings of the general low voltage switchboards.

The factory has also carried out a set of actions to improve the process and manufacturing flow of composite material components, including the optimization of the deburring room, both in dimensions and in the extraction system, the incorporation of a weightless handling system for the components manipulation by a sole operator, without any mechanical effort, or the new Torres Mill machining center for carbon fiber trimming operations, which has been put into production.

Among the actions to improve production capacities are the surface treatment line modification to carry out the sulfuric anodizing process at Ayuelas facility (Miranda de Ebro), the concentration of the raw material cutting capacity at Berantevilla logistics center (Álava) with the transfer and commissioning of the Berhinguer bar cutting equipment, and the entry into operation of a Spinner machining center mainly dedicated to tooling manufacturing.

Advances in process automation and digitalization have included the automation in Boecillo (Valladolid) of the adjustment process prior to the application of paint on large composite components, with the installation of a new dedicated robot and the successful completion of the first tests.

In the same category, the overhead crane movement automation in the assembly area of Aerópolis (Seville) facility has also been treated, which is scheduled to start up in the first quarter of 2023.

In the field of artificial intelligence, the team has completed the phase of integration of machining equipment in the machine learning project.

Also in Aerópolis, the renewal of the offices of the facility has been completed, with the air conditioning system upgrading, the renovation of the electrical and data equipment, the thermal insulation improvement of both walls and windows, and the integration of thermal recovery systems to optimize the energy consumption of the work center.

In the field of artificial intelligence, the team has completed the phase of integration of machining equipment in the machine learning project and activation of SCADA (Supervisory Control and Data Acquisition) for data collection and relevant information on the status of the equipment in real time. The system captures and analyzes the information, with the ultimate goal of reducing downtime due to corrective maintenance, anticipating machine downtime by analyzing key indicators and based on the predictive models developed. At the same time, the system will allow to increase the facilities' activity by optimizing the dedicated time to predictive maintenance and reducing the costs generated by failures.

Finally, and in accordance with the deployment of the continuous improvement methodology also to corporate services, the team has reached in 2022 the development, integration and consolidation of Kaizen level IV.