Our strife for perfection influences every step of the aircraft-making process: from the storage, quality control and the production organisation system to delivery and the after-sales services.
To assure absolute safety, we keep track of every activity of every single worker, as well as the history of every single part that gets assembled onto each aircraft.
As every aeroplane has over 5000 different parts and more than 96 sub-assembly systems, this is not a small task. We must ensure that every one works correctly, so we must know the details of where every part came from and how it was handled.
Outsourcing & incoming quality control
When we develop a new aircraft, we first make the first 5 prototypes at the facility - every single piece from scratch. This is enough to do all the testing and to see how the aircraft will behave in real world when finished. After this testing period, the design is frozen. We produce the complete documentation, choose the materials and decide about the technology used, make the molds, train the workers and outsource the production of certain parts too subcontractors.
As about 70% of all parts are produced this way, we need to enforce a very strict income quality control.
Every aircraft part which enters our facility is checked at least three times:
1.) First we have the INCOMING quality control: a part can arrive by courier or by import. As soon as it arrives at our building, it is checked. If the quality control officers find it safe and appropriate to use, the part receives a green sticker.
2.) The second step of quality control happens during the production itself:
The production of aircraft starts in the warehouse, which is the heart of the facility.
Here we keep all the parts necessary to finish the construction of the aircraft. The parts are organised in two ways - the smaller, more sensitive and easier to lose parts are stored in a robotic closet, the rest are stored on the shelves, sorted by the sectors on shelves with sector numbers.
To assure the ability to track and trace every single part, the sectors are connected to the computer software by the use of barcodes - every single piece gets a unique barcode, part number, serial numer and batch number as soon as it is accepted into the warehouse. The bar codes tell us all the information about a certain piece: where and when it was bought, how long it has been kept in the warehouse, who handled it, its weight…
Apart from taking care of the storage, the major task of the warehouse crew is to prepare trolleys for every individual aircraft..
Every aeroplane is made to order, with the exact configuration that the customer desires to have. According to the serial number of the aircraft and the specifications of the customer, the warehouse team then prepares every part to go on the aircraft and place them on the trolley with the same serial number as the aircraft's.
This trolley will follow the aeroplane from the beginning to the end, through the production line.
The production lane starts its life with an order by the customer. According to the desired specifications, a configuration/inspection sheet is written. All jobs, tasks and actions that need to be performed, as well as all the parts and sub-systems that need to be assembled onto the aircraft, are written onto the inspection sheet.
Every morning the warehouse crew prepares the trolleys with packets of parts, labeled with barcodes, that need to be assembled that day according to the inspection sheet.
When each process is completed and all the parts in every package used, the worker will unstick the barcode from the package and stick it to the inspection sheet. This is how we make sure that no part or process is ever forgotten!
At the end of every process, the worker has to sign the inspection sheet. At the end of the day, also the quality control manager checks all the processes again, and signs every inspection sheet.
This system of storage and traceability is unique to the Aviation Industry. It was originally patented by Toyota.
3.) The third step of quality control happens once the aircraft is already finished and waiting in the hangar. But before we can deliver to the end customer, every aircraft need to be thoroughly checked and flown for at least 5 hours by our test pilots. Every Pipistrel test pilot is a trained professional with many hours of flying experience on a veriety of aircraft.
If everything is flawless, the aircraft is given a general service at the end of this 5-hour testing period, and we can deliver a new aeroplane to the customer.
The Pipistrel Trademark - the guarantee for 100% safety and top quality
If you buy a Pipistrel, you are guaranteed to buy a thoroughly tested, safe and high-technology product. We worked hard all these years to maintain the quality level. For us, there is no such thing as being the second best - and our customers know that.
Some rock-solid proof of the trust that our brand has world-wide:
-When we presented Sinus to the public, we received 30 orders for it before the prototype even flew for the first time! In the first year alone, we received over 100 orders fir this aircraft!
-When ordering Taurus, people are prepared to wait for over a year for the aircraft to be finished and delivered. They are even prepared to pay 100% advanced payment for the aircraft.
-Our newest aeroplane Arcus isn't even fully designed yet and we already have the first orders for it!