This seven-figure project involved 12 months of extensive planning before the 14-week program began on-site.

The result was a highly complex production line relocation delivered on budget, on time and with zero incidents.

A team of six electricians, ten mechanical experts, a full-time project manager and a Health and Safety manager were deployed by AIS Vanguard, along with the support of specialist subcontractors for geometric machine alignment and software decommissioning, reprogramming and recommissioning.

The full scope of work required AIS Vanguard to deliver complete production line relocation and mechanical and electrical management. This involved disconnecting each fixture, dismantling the equipment, and lifting and loading it onto a curtain-sided wagon before relocating, installing and recommissioning each one.

Meticulous handling and high levels of lifting accuracy were crucial throughout. The team provided a complete power assessment for each fixture to check compliance and advise of upgrades and carried out LOLER inspections on fixtures with their own lifting and moving equipment, such as mini hoists and jib cranes.

As Safran Nacelles needed to remain operational throughout the move, a phased approach was necessary, essentially moving the front end of the production line to the new site while work finished at the end of the line. This transition allowed production to continue uninterrupted.

Segregation barriers were used to protect Safran’s equipment and the AIS team throughout the programme, with barriers moving as work progressed. Minimum impact equipment was also used, including electric valour cranes, LPG forklift tricks and electric Mobile Elevated Work Platforms (MEUPs) to protect air quality and mitigate the risk of fume egress.

The most time-sensitive part of the project involved a specific six-week critical path to relocate Saffran’s test rig – a vital piece of equipment used to test all Safran-made components before they can be released to customers.

AIS Vanguard called on its extensive machinery relocation expertise and best practice methods to design efficiencies and time-savings into the programme and minimise downtime of this critical piece of equipment. One strategy included labelling all rig cables in advance of the shutdown. This preparatory work shaved two days from the six-week programme, a crucial saving that helped meet Safran’s timescales and commercial objectives.