DGA Essais en vol
“Air resources division”
The challenge
Manual handling of heavy wheels putting staff at risk
The solution
Replacing manual lifting with safer handling methods
The result
High user acceptance and a solution ready for wider rollout
The company
DGA Essais en vol is the reference centre for French aeronautical systems. It carries out testing and provides expertise across all types of aircraft, their equipment and their weapon systems.
The directorate operates across two sites, Istres and Cazaux. Within this structure, the Air Resources Division (Moyens Aériens) is responsible for aircraft maintenance, explains Sébastien D., Deputy Head of the Support Department.
This includes around fifteen aircraft and approximately ten helicopters.
The division is supported by a team of just under 90 people, consisting of mechanics, electricians and electromechanical technicians, all responsible for aircraft maintenance.
“It’s incredible for us”
– Sébastien D.
The challenge – Manual handling of heavy wheels putting staff at risk
At the base, one recurring issue concerns the maintenance and replacement of aircraft wheels.
In 2022, preventive actions were planned to address manual handling tasks that generate musculoskeletal disorders.
A working group was established, and several problematic tasks were identified, including the handling of wheels.
The directorate operates across two sites, Istres and Cazaux. Within this structure, the Air Resources Division (Moyens Aériens) is responsible for aircraft maintenance, explains Sébastien D., Deputy Head of the Support Department.
This includes around fifteen aircraft and approximately ten helicopters. The division is supported by a team of just under 90 people, consisting of mechanics, electricians and electromechanical technicians, all responsible for aircraft maintenance.
During maintenance operations, the wheels must first be removed. This operation involves lifting the wheel, placing it on a press, applying pressure to the tyre using the press, then removing it, repositioning it vertically and carrying out the necessary interventions.
These handling operations were previously performed manually, including on Rafale Marine wheels weighing more than 80 kg.
The solution – Replacing manual lifting with safer handling methods
Sébastien D. and his colleague Patrick L., Head of the MA/VECTOR Group, were tasked with identifying solutions. It was at the Préventica trade fair in 2022 that they met Hovmand and concluded that, with certain adaptations, a Hovmand lifter equipped with a special tool could be considered.
This led to the design of a dedicated tool: a clamp capable of gripping the wheel on both sides, lifting it and moving it from a horizontal to a vertical position using the lifter.
Hovmand supported the development of a highly personalised, made-to-measure solution, while ensuring that it could be reproduced for other wheel workshops within the Air Force.
The result – High user acceptance and a solution ready for wider rollout
The result was a very high level of satisfaction among the mechanics using the solution, including the most experienced personnel, some of whom were initially reluctant and accustomed to long-established working methods.
“One week was enough for everyone to see the practical value of the lifter fitted with this special tool. It makes our lives easier.”
Sébastien D. adds:
“After a visit, our colleagues from the SIAE de Bretagne unit told us that the solution was excellent and that they would need the same equipment as well. In principle, we would like to make this type of equipment available across the Air Force and the DGA, even if this requires certain adjustments to suit different workshop configurations.”
“In 14 months, we identified the issue, validated the concept of the lifter, contributed to its design and ensured its commissioning together with Hovmand. This result is incredible for us,” explains Sébastien D.
He emphasises that this timeline was achieved thanks to the involvement of everyone, from prevention teams to the release of funding, as well as Hovmand, whose proposals and on-site presence contributed to the final solution.
He adds: “I am very proud of this concrete and operational solution.”