Material procurement remains a significant challenge in the aircraft interiors sector following the aftermath of the pandemic, with metals and plastics particularly affected, suggests Neil Cairns, the chief executive at UK-based Acro Aircraft Seating.
“While there are indications that metal prices will stabilize in 2024, this remains a persistent concern for us,” he says.
In response to these challenges, Acro is working toward establishing long-term agreements with suppliers to ensure a stable and reliable source for material and parts procurement.
Cairns says global shipping delays, exacerbated by the crisis in the Middle East, have further complicated supply chain dynamics and this has led to increased lead times, forcing the company to resort to air freight for certain parts deliveries to mitigate disruptions.
He says escalating energy costs and the high cost of living in the UK continue to exert pressure on production costs, adding another layer of complexity to operations.
Lessons from the pandemic have led Acro to vertically integrate some key elements of the supply chain. “This resulted in setting up Acro composite manufacturing, and we are now fully vertically integrated for all composite manufacturing,” he says. The company also invested in machining capability that enables it to produce most of its machined parts, according to Cairns.
In the process of rebuilding supplier relationships, Cairns has seen some changes in supplier behaviors including a considerable extension in supplier lead times. Additionally, he says the repercussions of the disruptions during the pandemic have led to an increased frequency of quality concerns, which bring significant operational challenges.
Acro has established processes to consistently monitor the quality of materials and parts received from its suppliers. This involves continuous tracking of key metrics such as the number of quality escapes, as well as performance indicators like defective parts per million and on-time-in-full metrics. Cairns says tracking these metrics enables Acro to gauge and measure the suppliers' performance in delivering high-quality components.
“In adherence to industry best practices, any design concessions proposed by a supplier undergo a thorough review and must receive approval from Acro before implementation into production," he says. "Additionally, we ensure that our suppliers conduct first article inspections, which are subsequently reviewed by Acro."
These rigorous measures are integral to quarterly business reviews with all suppliers to ensure high standards of quality throughout the supply chain.
Airlines are increasingly emphasizing that suppliers should align with their sustainability outlook, and according to Cairns, Acro is continuously working with its suppliers to explore the use of materials containing higher recycled content or those that are generally less harmful to the environment.
“Our commitment to sustainability extends to every aspect of seat design and material choices, with a particular focus on foam technologies for seating cushions, eliminating the use of harmful chromate compounds in the coating and plating process,” says Cairns. Acro also is seeking sustainable synthetic leathers for seat dress covers.
Whenever possible, he says Acro prioritizes suppliers certified under AS9100 and with ISO accreditation. “Additionally, our ongoing efforts in testing and auditing the recyclability of our Series 9 seat mean that we are consistently exploring ways to collaborate with suppliers to ensure that materials and parts are viable for recycling when seats reach their end of life,” he says.
