Minimizing downtime, maximizing quality

Manufacturing engineer Kevin Egbert leads a team of MRO professionals focused on repairing and returning galley insert equipment into service with both speed and quality.

Airlines and their cabin crews understand the importance that coffee makers, ovens, and other galley equipment contribute to the in-flight experience.


Behind that equipment are skilled professionals who ensure these devices continue to function reliably flight after flight, sometimes for decades. At Collins Aerospace in Lenexa, Kansas, manufacturing engineer Kevin Egbert has dedicated 27 years to keeping these essential cabin products operational.

"Our business services anything that is basically flying in the air," explains Egbert, a Senior Manufacturing Engineer. "Any airline that's running a product that we've produced, we're here to fix it for them."

A lifetime of expertise across decades of products

The Maintenance, Repair, and Overhaul (MRO) side of aircraft cabin products presents unique challenges, requiring expertise that only comes with years of dedication. Throughout his nearly three-decade career, Egbert has developed an extraordinary depth of knowledge across products spanning generations of aircraft.

"We see things that have been 30 years out in the field. We might have a coffee maker that was built in the 1980s that'll come in for service," Egbert notes. "We have to have at least a working knowledge and understanding of what might be wrong, how we might need to test it.”

This breadth of product knowledge represents a career-long commitment to learning. When faced with older, unfamiliar products, Egbert explains, "We dig into the technical documents and try to get some guidance. We try to absorb what we can from the documentation, then bring it back to the line and help out that way."

Egbert and his team must have a strong depth of knowledge across entire portfolios so they can understand how to repair equipment that can be decades old.

The Detective: Problem-Solving Expertise in Action

Egbert's role often makes him a "first responder" when issues arise, requiring investigative skills that he's honed over decades to determine whether problems stem from the product itself, testing equipment, or tooling.

"You really do have to do a little detective work," Egbert says. "Am I looking at a product that's bad, or am I looking at a test fixture that's bad? Making that determination sometimes takes a lot of trial and error to rule things out until you can come to a root cause."

This problem-solving approach extends to improving productivity throughout the repair process. Under Egbert's guidance, improvements range from small adjustments to complete restructuring of production lines.

"We've done improvements as small as moving a monitor from one side of a workstation to the other," he explains. "Doesn't seem like a lot, but when that technician is working on his product and needs to see the documentation, turning from side to side sometimes is very challenging. That small thing is an improvement."

The engineer's mission: speed with quality

For airlines, minimizing the time that galley equipment spends in repair is critical. Egbert takes personal responsibility for ensuring rapid turnarounds without compromising quality.

"The speed at which we do repairs is really important," Egbert emphasizes. "The airlines count on us to get things done in a timely manner. It's akin to something that you might have at your house that breaks down. You don't want that out of your house for two months. You want it back as soon as you can get it."

This pressure to deliver rapid repairs while maintaining quality has driven Egbert to continuously refine processes. "The improvements we look at, number one, are throughput. Obviously, we want to do things faster, get more things done during the day," he explains. "We've also tried to improve the way that they put them together, maybe to reduce errors, maybe to give them some fixtures and things that they can do the job a little bit better and not make mistakes."

The collaborative leader

Over his career, Egbert has become a mentor and knowledge resource for newer team members, fostering a collaborative environment that leverages everyone's strengths.

"We have a lot of product knowledge in our group, some people that are brand new and some people that have been here for a lot of years," he notes. "We, as a group, collaborate with one another to help each other out. If there's an issue that maybe someone that's new hasn't experienced before, maybe somebody else on the team has."

This collaborative approach led to one of Egbert's proudest achievements, a project to increase productivity on the beverage maker repair line. "That took a lot of effort by a lot of different groups," he says. "We had people from the production line helping out. We had production supervisors, manufacturing engineers, lots of support staff to understand how the process would work the best."

Egbert (right) has become a mentor and knowledge resource for newer team members, fostering a collaborative environment that leverages everyone's strengths.

The heart behind the technology

As passengers enjoy their coffee at 30,000 feet, they may not think about the engineering expertise that keeps that coffee maker functioning—sometimes after decades of service. But behind each working galley insert is a dedicated professional like Egbert, who ensures the reliability of these essential components of air travel.

"I work with some really fantastic people. We all kind of have a common goal," Egbert says. "When you have a common goal, and most people here do have that common goal, things go smoothly, and you get a really good product."

Egbert's dedication to excellence, problem-solving ingenuity, and collaborative leadership continue to ensure that when passengers reach for that cup of coffee miles above the earth, the systems will work just as they should—a testament to the expertise and commitment of the manufacturing engineers who keep the cabin experience flying smoothly.


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