In a quiet industrial warehouse located in Northern Ireland, a remarkable sight unfolds: a robot arm diligently opens and closes an airplane meal table. This robotic task is not just for show; it has been programmed to execute this motion 28,000 times, running day and night for over a week. Despite the repetition, there is no reward of a snack at the end of the shift. Gerald King, the head of engineering at Thompson Aero Seating in Banbridge, explains the significance of this task. He mentions the ability to measure the force the robot arm applies, noting that any increases could indicate heightened friction.
Thompson Aero Seating specializes in crafting high-end first-class and business-class airline seats, which are typically found in the aircraft’s front sections and feature luxurious privacy enclosures, built-in entertainment systems, and ample legroom. The company boasts a cutting-edge £7.5 million testing facility created to evaluate the safety and durability of these seats. Within this facility, crash test dummies are secured to the seats and propelled down a short track at astonishing speeds to mimic the intense impact of flight emergencies, testing the structural integrity as they simulate an exposure to 16 g’s of force. Notably, this testing facility is the only one of its kind on the island of Ireland.
According to Invest NI, a regional economic development agency, approximately one-third of the world’s airline seats are produced in Northern Ireland, underscoring the area’s significance in aircraft seat manufacturing. Thompson, which became part of a Chinese conglomerate in 2016, is one of the select few companies in the region engaged in this specialized trade, producing around 1,500 seats annually. Other prominent manufacturers in Northern Ireland include Collins Aerospace, located in Kilkeel, and Alice Blue Aero in Craigavon.
The global pandemic transformed the demand landscape for aircraft seats, with production grinding to a near halt as COVID-19 spread. Numerous aerospace manufacturing firms were forced to reduce their workforce significantly, and Thompson saw its staff size slashed by half, resulting in profound financial losses. However, the industry has begun to recover as travel resumes. Unfortunately, manufacturers now face a shortage of skilled labor to meet the renewed demand, leading to a difficult discrepancy between supply and demand. Airbus’ chief executive highlighted the shortages in June, alluding to the challenges in sourcing not just seats, but various cabin components.
Nick Cunningham, an analyst tracking the performance of another seat producer, Safran, points out the twin issues at play: the loss of hands-on manufacturing expertise during the pandemic and the challenges in transferring skills to younger generations. A significant bottleneck has emerged as seat manufacturers struggle to have their products tested and certified by third-party entities also grappling with labor shortages.
Amid these challenges, Thompson Aero Seating has an advantage with its in-house testing capabilities, allowing it to better adapt to customer needs. Colm McEvoy, the vice president of corporate accounts at Thompson, emphasizes that while they can currently meet their clients’ demands, they approach new client acquisitions with caution. The company, which employs over 650 staff members, has stated several job vacancies, competing against other manufacturers for top talent.
To boost production rates further, Thompson has laid out a five-year growth plan. Eoin Murray, the operations manager, describes a factory floor bustling with activity as skilled workers meticulously assemble each seat, ensuring every detail—like the incorporation of advanced entertainment wiring—is flawlessly executed. With a 100-hour assembly process for the most intricate designs, there is immense emphasis on optimizing production lines.
Moreover, innovative tools, such as adjustable jigs and utility belts with strategically arranged tools, facilitate greater efficiency amid the nuanced assembly processes. Through this approach, workers rehearse critical steps of the seat assembly, developing skills similar to the precision required in constructing complex Ikea furniture.
With ongoing demands for new designs and technologies, Thompson is consistently exploring ways to enhance its seats. Airlines are increasingly requesting state-of-the-art entertainment options, like the large 32-inch screens now featured in their high-end offer. Each seat incorporates luxurious materials such as leather, with the capability to transform into fully flat beds during long-haul flights.
Industry analyst Marisa Garcia notes the high caliber of Northern Irish seat manufacturers, affirming their expertise and capability to meet growing demands. She emphasizes that while challenges exist in the supply chain, the market for innovative seating solutions remains robust, with increasing demand from both airlines and passengers for top-tier flight experiences.
