Unique is a term that is often overused, but in the case of Aerosud, it is more than apt. From its base in South Africa, the company has become the biggest manufacturer of aircraft parts and assemblies on the continent. More than that though, Aerosud’s versatility has led it to be dubbed the ‘Swiss Army knife’ of aerospace manufacturing.
“OEMs and super tier ones in the industry see us as a one-stop shop,” COO Russel Grefen explains. “We do everything from simple metallic manufacturing to textiles.”
Aerosud’s diverse high-volume manufacturing capabilities have been built up over the years with a focus on vertical integration. While it mostly works on build-to-print contracts, the company still has significant design engineering capabilities, enabling it to meet a huge range of demands. While such independence would be a positive for any company, it has proved especially beneficial for Aerosud considering its geographical distance from traditional aerospace supply chains in Europe and the US.
“To tackle our remote location, we’ve really invested in ourselves and vertically integrated,” Russel says. “We operate from one campus, with manufacturing right next door to engineering, which works to our advantage.”
One-Stop Shop
To ensure its manufacturing facilities remain at the industry’s leading edge, Aerosud makes regular investments into the latest technology and processes. Among the company’s most recent additions are improved aluminium welding capabilities and digital tools for supply chain management.
“In terms of aluminium welding, that’s where we see our real niche, as a sole supplier of thin-walled aluminium welded products,” Russell reports. “On the digital front, we have invested in various e-tools and digital management systems for when we need to make use of the European supply chain.”
Backed by its proven track record, Aerosud has forged strong relationships with its partners. For some OEMs, the company has become the sole supplier of integral aircraft components, like track cans – an outward display of the trust these clients have in Aerosud.
“Track cans are a Class 1 component that need thin-walled aluminium welding, which requires highly technical manufacturing processes and technologies,” Russel states. “We have been manufacturing those for OEMs since the late 2000s. These companies have committed to us because they know we can deliver.”
Trusted by the Best
Aerosud does not take the trust of its partners for granted and this is evident in the company’s willingness to make aluminium welding one of its core priorities. The business is also unafraid to take on new challenges, such as the task they were recently set by Airbus.
“Airbus is planning to ramp up their single aisle aircraft, the A320. As their sole supplier, they came to us and asked what we would need to increase our capacity and hit their targeted future rates,” Russel reveals. “We are now eighteen months into that project working closely with Spirit Aerosystems and Airbus to establish new machinery that will enable us to deliver at the required Airbus rates. This collaboration speaks volumes about the trust they have in our ability to produce complex components at scale.”
Manufacturers do not achieve a reliable reputation for quality by chance – the proof, for Aerosud at least, is in the plane. Technology and machinery often take much of the credit, especially in our tech-driven world, but Russel argues that Aerosud’s people are the real difference makers.
“We’re not as automated as many companies in Europe, so we rely on skilled people,” Russel affirms. “Our approach is not just about the practical work either – we understand that, in order to get the most out of employees, you need teamwork and good relationships.”
Partnering Up
With this in mind, Aerosud has recently explored the psychology behind company culture, with a focus on how teams operate and work together. Specifically, the business has collaborated with behavioural science firm Grid International to help shape a more co-operative and harmonious organisation.
“Over the last eighteen months, we’ve worked with Grid to drill down into how people behave and the ways to foster synergies in the workplace,” Russel remarks. “You can invest in machines, but if you can’t get people to align, you won’t be productive. It’s an in-depth project, from top to bottom, and it’s even seen us take people off the shop floor for discussions on culture and how to work together.”
Harnessing the power of a collaborative work environment that values both people and machinery, Aerosud has established a strong foundation as a vital partner in the aerospace industry. The company is now hoping to achieve its most substantial growth for some time, securing new business and expanding into new markets. In order to do that on a scale befitting the manufacturer’s ability and potential, Aerosud is on the lookout for a suitable industrial partner that can help secure, and optimise, the organisation’s future.
“Working with the right industrial partner could help us gain access to new markets and OEMs,” Russel notes. “It’s a global search, where financial strength will be viewed as an asset too. We need a partner that can really help us grow in the long term.
“On our side of things, alongside the search, we have gone through a major restructuring, especially at top management level, as well as real concentrated efforts to improve our operational efficiencies. It’s all part of finding a partner that is a cultural fit, with the same vision as us. That’s the turbocharging we really need.”
