Over the summer, the Airbus A321XLR received the first of its two type certifications. This milestone followed what was an extensive testing and certification process.
When the first aircraft is finally delivered, it will be the end result of a huge team effort. This involves the dedicated work of the customer programme, manufacturing, flight line and delivery teams.
In this article, Airbus provides us with a deeper insight of just what this process involves.
The Journey Begins: From Purchase to Production
The journey of an A321XLR starts long before it ever touches the final assembly line. Each customer is assigned a dedicated Customer Programme Director, responsible for overseeing the entire aircraft development process.
Marie-Pierre Demarez, one such director, explains the intricate process involved. “From the moment the purchase agreement is signed, I am accountable. I ensure the on-time, on-quality, and on-cost delivery of all aircraft in the customer’s XLR fleet.”
Once an airline has made a purchase, they can customize their aircraft to meet specific requirements.
This includes selecting system and cargo options, external livery, cabin design, and more. Given that the XLR is a new aircraft variant, the initial customization requests required extensive collaboration. These take place between Airbus, the customer, and various equipment vendors.
Integrating the A321XLR into Existing Production Lines
After the design phase is complete, production can begin. Airbus manufactures the main aircraft sections separately and then assembles them together at the final assembly lines (FALs).
Justin Mörker, responsible for integrating the XLR into the FALs, explains the challenges and strategies involved.
“Integrating a new aircraft type into existing production lines requires careful planning and coordination. We’ve adopted a staggered approach, starting with one FAL.Then gradually expanding to others to share lessons learned and address any challenges proactively.”
Overcoming Challenges and Ensuring On-Time Delivery
The integration of the XLR into the FALs is a complex task. It requires close collaboration between centralized teams and local launch team leaders.
Thomas Luckel, the XLR FAL Launch Team Leader in Hamburg, highlights the challenges of introducing a new aircraft type. “The new variant must be integrated into an already busy production line. We had to ensure that every aspect of the process was ready and could be integrated smoothly. This is to avoid disruptions to the production of the A321neo.”
The Final Steps: FOT and Delivery
Once the aircraft passes through the FAL, it undergoes a series of rigorous tests to ensure its readiness for flight. The FAL Operational Test (FOT) is a crucial milestone in the process. It verifies the aircraft’s technical conformity and grants the clearance for ground and flight testing.
Jannis von Hein, Head of Maintenance Engineering, Planning & Logistics, emphasizes the importance of meticulous preparation for the FOT. “Our team works closely with development and customer teams. This is to ensure that all modifications are installed correctly, and that the aircraft is ready for delivery.”
After successfully passing the FOT, the A321XLR aircraft moves to the flight line for final ground and flight tests. Once these tests are complete, Airbus delivers the aircraft to the customer for the Technical Acceptance Process.
This is the moment when the customer can see their new aircraft for the first time and witness the culmination of years of hard work and dedication.
Final Delivery
Once the aircraft makes its way through the flight line, there is an industrial handover and the aircraft moves to a delivery centre. The customer finally arrives onsite to complete the Technical Acceptance Process and the title transfer.
Customer Programme Director Marie-Pierre Demarez sums it all up. “Five years of effort went into preparing these first customer versions of the XLR, and seeing their first flights makes it all worthwhile!”
As the A321XLR enters service, it promises to redefine long-range single-aisle travel, offering passengers a more comfortable and efficient flying experience.
With the first A321XLR delivered, the focus will shift to ensuring a smooth and efficient production ramp-up. The A321XLR has the potential to transform the aviation industry, offering airlines a flexible and fuel-efficient option for long-haul flights.
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