F-Stage Case Study



Assystem Technologies was engaged by a major OEM in the Aerospace sector to carry out a major investigation and redesign of the Single Aisle Assembly line in Broughton. The key focus of the project was to eliminate Stage F on the wing build process, which was seen as impacting on the critical path and therefore preventing the build being completed within the optimum potential timeframe.

Assystem Technologies delivered the customer a full turnkey solution using an Integrated Project Team (IPT) approach to offer lineside support, providing an integrated manufacturing solution delivered using a long-standing manufacturing partner.


To deliver our client a comprehensive engineering solution, we provided an integrated, multi-disciplined team across the full product lifecycle covering:

  • Feasibility studies
  • Design
  • Tolerancing
  • Manufacturing Engineering
  • Tooling
  • Manufacture and installation – delivered through integrated working with an established manufacturing partner

Our solution offered an integrated product team approach, with tooling and design support provided by our Preston team.

Overall, our team were able to identify a 20 hour STV (Standard Time Value) saving per wing build and eradicate a production bottleneck through the elimination of Stage F on the wing build process.


  • Primarily, the new tooling solution provided the customer with a significant STV saving per wing build, contributing positively to the drive to address cost and programme delivery challenges
  • Savings defined and implemented to meet increased customer demand and improve TAKT time (the maximum amount of time in which a product needs to be produced in order to satisfy customer demand)
  • Improvement of operator ergonomics and Health and Safety aspects