October 18, 2024
Earlier this year, Spark Ops Metalworks was approached by a major aero client to develop a specialized solution for their maintenance, repair, and overhaul (MRO) facility in Macon, Georgia. This client, a leading aircraft manufacturer, has been expanding its MRO facilities across the southern U.S., including locations in Georgia, Tennessee, and Texas. The challenge? Their existing hangar space was limited, and maintenance tasks required space-efficient solutions to streamline operations.
One of the biggest challenges our aero client faced was finding a safe, efficient way to store aircraft seats during maintenance. Removing all 76 seats from an E-175 aircraft is a labor-intensive process that requires multiple personnel to carefully uninstall and store them, ensurig both safety and efficiency. Storing the seats on the hangar floor not only creates clutter but also takes up valuable floor space needed for other critical operations.
Spark Ops addressed this issue by manufacturing a modular maintenance platform using DSS components designed to streamline seat storage. With this innovative platform, the MRO facility can store seats securely on the platform itself, rather than on the floor, freeing up essential workspace during aircraft repair.
The platform provides a designated area for seats and ample space to hold tools, toolboxes, and other equipment. Additionally, the open space underneath the structure allows storage for specialty parts, extra toolboxes, or other items required for the job. This frees up significant floor space in the hangar, allowing maintainers to work more safely and efficiently.
A team of dedicated Spark Ops employees, including CEO Bryan and seven team members, traveled to Georgia to complete the project. The crew efficiently assembled three custom structures for the aero client on-site in just two days, showcasing the speed and practicality of the height-adjustable modular platform.
The platform was constructed using the patented aluminum building components, all manufactured in-house at Spark Ops. The structure resembles assembling a LEGO set, requiring only minimal tools—typically an impact drill and some good old-fashioned handwork. No welding or extensive tools are required, making it an easy and quick assembly process.
By reducing the need for ladders, scaffolding, and scissor lifts, the platform optimizes space within the hangar, leaving more room for essential maintenance tasks. While some specialty ladders or lifts may still be necessary, the modular design significantly reduces the need for excessive equipment.
Following the success of the Georgia project, Spark Ops has maintained an ongoing partnership with this aero client. The team is now working on providing similar modular platforms for their MRO facilities in Tennessee and Texas.
The collaboration between Spark Ops and our aero client highlights the various capabilities of our modular platform system, which is adaptable to a wide range of industrial needs. We look forward to continuing our partnership with this client and other companies seeking practical, space-saving solutions for their plane maintenance operations.
