Icon Aircraft Factory Tour

Jorge Meraz: Folks, today on "Crossing South," we get to see some really cool amphibious planes being produced in Baja, coming to you now.

♪♪♪ ♪♪♪ Jorge: You know, manufacturing is a big part of the region here in Tijuana.

This is just one of many plants that have brought their operation to this city for assembly, for production, and the company we're in right now is called ICON, and they're very particular.

It's a very interesting product that they make in this plant, and the person that's gonna give us a tour of what's going on here, the operation, is standing right next to me.

Kevin, my man, how're ya doin'?

Kevin Golden: Good.

Jorge: Production manager, right?

Kevin: That's right.

Jorge: Okay, he's the man.

He's gonna show us how things are done.

Let's go.

Kevin: All right, let's go.

Jorge: Thank you, Kevin.

♪♪♪ Jorge: This plant produces a really cool plane called the A5.

Most small planes need an airport, but this thing can actually make it's landing on land or water.

They expanded a lot of their manufacturing to Tijuana, and so we wanted to check it out.

Being such a cool thing to make, we wanted to see the ins and outs of this leisure air-land-water vehicle.

Jorge: Manufacturing in Baja and Tijuana is super-important.

It's very--there's so many companies, international companies manufacturing here.

How has the workforce been, I mean, the Mexican workforce?

You know, how have they been in regards to this type of work?

Kevin: So this type of work is fairly new.

Once we came over into Mexico, we had a very intense or robust training that we took all of the employees through for laminating and bonding.

For the painting portion, it was more on-the-job because we feel more comfortable with the painters touching the part understanding the complexity of it because it's very complex to complete-- Jorge: So you need to learn it on the job.

Kevin: --so you need to learn it on the job.

Jorge: Wow.

Kevin: But we bring people in, we take 'em through our training for three weeks up to a month before we let them out on the production floor, but they're still not manufacturing parts yet.

We go through a core exercise.

We go through the detailing exercise in order for the employee or the new employee to get comfortable, laminating the part.

Jorge: So, phase one, your new entries are doing laminating.

Kevin: That's correct, right, that's correct.

Jorge: But you do have a manufacturing side here?

Kevin: We do have a manufacturing side.

Jorge: Those are employees that have gone to the next level?

Kevin: That's correct.

So we have A&P guys here that's helped building the final result of the aircraft.

We have bonding techs that also specialize in the closing of parts.

So, for example, we have a fuselage that we actually bond together, two skins-- Jorge: Oh, really?

Kevin: --that we mate together.

Jorge: So, if I understood the process correctly, it's comprised of multiple steps, but the first step is just as important as the last one.

This is the lamination part.

Kevin: So this is our first process of laminating.

Jorge: So, explain to me what that is though.

Laminating what?

Kevin: So laminating is we take a material.

We take this material and form parts.

Once we form the parts, we then take it into the oven for cure.

After it's cured-- Jorge: You put into an oven, heat it up, and then leave it for curing?

Kevin: Correct, and then, once that's done, it's de-tooled.

Once de-tooled is complete, then we have a trim-and-drill process, so it's a very broad process that we go through to creating a part.

This is the first phase of creating the part.

This is phase one, the most important-- Jorge: Is this a panel, a wing?

What is this?

Kevin: This is actually an aileron.

So the aileron is just the functionality for the wings.

It helps support the wings.

Jorge: It's within?

Kevin: Uh-huh.

Jorge: Okay, gotcha.

Kevin: The laminating portion is very complex although it's also simple.

Jorge: Right.

Is it a part?

Is it a thing where you want employees to go through that process, that way, when they're doing the assembly part, they already know what the guys behind went through and how to do the work that was the baseline, you know, by the time it gets to them, right?

I mean, they know how to do all that already, right?

Kevin: That's correct.

So we set a standard, right?

So that standard, coming in, we have work centers, Work Center A, Work Center B, Work Center C. Each one of the employees go through each one of those work centers.

So we're tryin' to create more of a cross-functional team opposed to--to set standard.

Jorge: Right, where there's one department, and, just, "This is only my responsibility," no.

Kevin: That's correct.

Jorge: You know how to do everything, the whole process, right?

Kevin: That's correct.

So, for example, this area right here is the fuselage skin, so the larger skins, right now, we completed skins through 181.

Jorge: This is the fuselage skin?

Kevin: This is a spar.

The main spar is the most important part of the aircraft because it's structurally sound to support the insulation of the wings, so this is the main portion, and then there's a MA-11, which is another portion of it, which I'll explain on the other side.

Jorge: Okay, heh-heh.

But, a "spar," where does that go?

Kevin: But the spar is more the center wing.

It's the upper portion of our aircraft, and it is super-complex.

Jorge: Oh, the wing?

So it's kind of like, on top, right?

Kevin: So the wing is up high.

Jorge: Yeah, I got you.

So this--centered would be?

Okay, so this would be over the fuselage.

Kevin: That is correct.

Jorge: All right, so that's an important part.

Kevin: That's a major part.

Jorge: So what are they doing?

Are they doing-- Kevin: They're actually tryin' to finish up laminating this, so this process requires them to use tools of measurement.

They're making sure that they're applying the lamination-- Jorge: Is laminating a function, or is it aesthetic?

What is--what are you doing?

Kevin: It's functional.

Jorge: It's functional?

So what is it?

What does that do?

Kevin: So it's plies.

It's one ply at a time.

It's one piece of laminate for-- Jorge: The whole thing?

Kevin: The whole thing.

Jorge: No way.

Kevin: Yes.

Jorge: So, in order to properly laminate the part, the workers have to use these molds.

It's very tedious.

Imagine, layer after layer.

It reminds me of the same mechanics of a 3D printer but done by human hands.

Kevin: So, these--molds, we use for several different things, so it just helps us locate hole sizes.

I mean, we identify everything, and our laminating team, once they get the instruction from planning, we take this piece over to the laminating shop, and that's when the magic begins.

Jorge: So is this the mold of something that they have to basically build laminating?

Kevin: Correct.

Jorge: So you have to duplicate this from scratch?

Kevin: From scratch.

Jorge: Wow, is this just--is this a laminated piece, or is this just the mold from-- Kevin: That's a mold for the laminated piece.

Jorge: Okay, gotcha, gotcha.

Kevin: In this area alone, just to complete a fuselage is 368 parts that are laminated to complete one full aircraft.

Jorge: You guys got a big operation for what seems to be a leisure product.

How many people are buying these planes?

Kevin: Our sales are really, really good, so a lot of people are really buying.

Jorge: Wow.

Kevin: Like, this year, we're completely sold out so-- Jorge: Probably not only the U.S., right?

You're probably selling it around the world?

Kevin: Not yet-- Jorge: Not yet?

Oh, really?

Kevin: --but we're goin' international.

Jorge: So this is only U.S.?

Kevin: This is only U.S. Jorge: There's a huge market for this?

Kevin: Yes.

Jorge: Is it a hydroplane, or what would you call it?

Kevin: No, it's an amphibious.

Jorge: Amphibious plane.

So the next area I see is the trimming of the fuselage skins.

I have to say, I don't see an aircraft yet.

It took some imagination, but you gotta trust the process, right?

Kevin: That is one of our fuselage skins.

We actually hand-trim.

Jorge: That's the fuselage skin?

Kevin: Yes.

Jorge: Really?

Kevin: So, we have a scribe line that he comes and he trims based off of that scribe line, so he's actually cutting this line so, when we do the bonding process, everything mates appropriately.

He'll go through it and trim all of the edges to the scribe line, and then that's when we pass it over to inspection.

Jorge: Is this the actual skin of the plane?

Kevin: That is the actual skin of the aircraft.

Jorge: What material is that?

Kevin: This is the same material that we use over in that-- Jorge: The laminating?

Kevin: The laminating, yeah.

Jorge: But is it more layered or-- Kevin: It's way more layered.

Jorge: Way, way more-- Kevin: More layer, yeah.

Jorge: More--a lot denser.

Kevin: Yes.

Jorge: Gotcha.

Kevin: And this is really time-consuming.

Right now, we're getting through it in about four days to laminate a skin.

Jorge: What is the core, you know, ingredient?

What is the material?

What is it?

Kevin: So, this is 100% carbon fiber.

Jorge: Gotcha.

Amazing.

Amazing how, you know, even products like the core materials that come a long way, right?

I mean, 'cause, at the beginning, planes were made of, what, aluminum?

Kevin: Aluminum.

Jorge: Right?

Kevin: Aluminum, mm-hmm.

And this is more structurally sound than aluminum.

Jorge: Really?

Kevin: Yeah.

Jorge: Wow.

Jorge: So that part was the trimming and the drilling.

Next up are the subassemblies where the majority of the parts will be prepared to be installed into the aircraft.

This is where the parts begin to look like something that resembles an actual plane.

Kevin: So majority of our parts has to come to subassembly before we install it in final.

And here, like, we have two engines that's in the process of subbing.

Jorge: This is the engine?

So I wonder, like, you know, just a car mechanic sees this, what does he see?

You know, like, how similar or de-similar?

Kevin: It's super-similar.

Jorge: Yeah?

Kevin: Yeah, it's super-similar.

I mean, the difference is like we have the fuel tank separate.

I mean, even in automotive, we have fuel tanks separately.

We have a firewall that we install.

So the firewall is just where we seat the engine, so any fluids, liquids-- Jorge: Stay here.

Kevin: Yes, and then our thermostat as well, so everything is kind of broken apart.

Jorge: Is this kind of, like, insulated somehow?

Kevin: Yes, it's 100% insulated prior to installing it on the aircraft, right?

And then we have a 24-hour cure once we put it inside the aircraft before we put the engine.

So we do our prop subassemblies here.

We do a balance here on this fixture.

So we get the prop blades.

We put it on this fixture here, and then this is where we do the balance.

Jorge: Balance?

Kevin: Uh-huh.

So we have to balance the props prior to installing it on the aircraft.

Jorge: What's the importance of balance on a prop?

Kevin: So if you don't balance a prop correctly, you're gonna have a problem vibrating like this, and it's gonna scare the Jesus out of you, right?

So you wanna make sure it swings very well.

Jorge: It needs to be balanced.

Kevin: Right, it needs to be balanced, just like your tires.

Jorge: It needs to just go like-- Kevin: Correct.

Jorge: Smooth.

Kevin: So if you buy new tires and don't balance the tires-- Jorge: Right, all shaky ride, right?

Kevin: All shaky.

Jorge: All of this looks very sophisticated.

It's a pretty complicated production process.

It has very specific standards because the life of the end user is at stake.

I was curious as to why this facility was located in Tijuana and not elsewhere, maybe Asia or back in the states.

Jorge: Your whole operation is here, or do you have another plant somewhere else?

Kevin: We have another plant in Vacaville, California.

We actually originated there, and we moved to Mexico five years ago.

Jorge: Easier here or-- Kevin: Easier.

Jorge: Easier?

Kevin: Easier, yeah.

So all of our composite-manufacturing abilities, we brought in experts.

We had lots of support in order for us to start manufacturing our own composite parts.

In the first couple of years, we were able to do that, and from there, we started manufacturing our parts, painting all of our parts, and then we brought final assembly here two years ago, so now were doing the final assembly here, ourself.

In fact, I'm originally from the states.

I've been here for-- Jorge: You started over there?

Kevin: I started over there, and I've been with ICON since 2014.

Jorge: So what was your reaction where, like, "Kevin, we have news for you.

We're goin' to Tijuana--" hah-hah-hah-hah.

Kevin: Honestly, I was like, "Okay, I've never been.

Let's try it."

Jorge: "Wherever the job takes us," right?

Kevin: Right, wherever it can help the company, right?

So-- Jorge: So we continued our tour, and we started having that "eureka" moment where the jigsaw puzzle starts taking shape, right?

But there were still some important steps left.

Kevin: This is the shell of the fuselage.

This is a very, very complex portion as well.

So right now they're doin' the fitment for the engine cowls so the muffler fairings, the upper engine cowl, they're doin' a whole fit so-- Jorge: Are they gonna put the whole thing together or just a few parts here?

Kevin: Just a few parts because we're gonna drill holes to make sure holes are aligned, right?

Jorge: At what point do they put all the mechanical parts?

Kevin: That's on the final side.

Jorge: The final side.

Kevin: This side over here is more focused on cutting out the headlights.

We install the hood here.

We do certain functionalities of the parts.

For example, we drill holes.

We bond this guy.

Jorge: All these orifices, they are the ones that are drilling 'em?

Kevin: That's correct.

This is where we close.

So, remember, at the beginning, I showed you a skin.

Jorge: Yeah?

Kevin: So this is one skin; this is another skin.

Jorge: Ohhh-- Kevin: This is where we bond them together.

So you got two shells.

Now we're waiting for some additional parts, which is gonna be the spar, and we're gonna go, "sh-click."

Jorge: Do you glue them?

Or what is it?

Kevin: Yes, so it's a PTM&W, which is a adhesive.

It's like a glue.

We come in, and we glue each side, and we squish one side, and then we glue the next side, and we squish the next side until you have one formed fuselage like that.

If you see this area that's kind of sanded, so the glue would be here, and as the parts mate together, they kind of go over each other like-- Jorge: Oh, they overlap.

It's not like this.

Kevin: It's not like this, no.

Jorge: Okay, gotcha.

And that big ole, like, chassis-- Kevin: The spar.

Jorge: --you know, does that go here when they put it together?

Kevin: So this goes-- that actually goes here.

It's several assemblies, so that main piece actually goes here.

Jorge: And then they put it together?

Kevin: And then they put it together.

Jorge: Oh, my goodness.

Kevin: So it all works together.

It's like one systematically great machine.

Jorge: So these are your laminated parts.

You wanna bond them together.

This is where you do that?

Kevin: Right?

And then-- Jorge: Is that like the glue, the adhesive?

Kevin: Yes, that's the adhesive.

Jorge: Some industrial thing, right?

Kevin: Mm-hmm.

So, and then certain parts-- like, we bring 'em from laminating, and we bond ribs in.

We put in certain functionalities.

Jorge: The workforce that Kevin has in this plant is very flexible.

Due to the cross-training that they have, they don't miss a beat.

Jorge: And you mentioned that you have workshops where an employee doing something here, you don't want him to just know this.

You'll move him to another part to learn the next.

What are the benefits of that?

Kevin: It's made for attrition.

It's also made for the flexibility of staff, right?

Because, if you have a high attrition, which we do not, but we did once, then you're gonna impact an area.

So in order to stabilize a lot, you develop cross-training, and once you have cross-training in place, you can utilize your staff how you need to.

Jorge: How you need to.

Kevin: Yeah.

Jorge: We were almost at the end of the production line, but there was still a very vital step left to do.

Kevin: Lastly, I'll take you guys through paint.

This area is a little-- not controlled.

There's no nice air-conditioner, none of that stuff goin' on back there.

Jorge: So it's gonna be hot?

Kevin: It's gon' be a little different.

Jorge: Heh-heh-hah-ha-ha.

Kevin: I won't say "hot."

Jorge: "A little different," huh?

Kevin: It's just a little different.

Jorge: Okay, I'll remember that phrase.

Kevin: Ha-ha-ha-ha-ha-ha.

Jorge: "What is it?

Bad?"

"It's a little different."

Kevin: "It's a little different."

Ha-ha-ha-ha-ha-ha.

Jorge: When somebody asks me, in the future, "It's pretty bad, right?"

I'm just gonna go, "It's a little different."

Kevin: Yeah, that's what you could say about the tacos.

Like, "Yeah, it's just a little different."

Jorge: "The food's pretty bad?"

both: "It's a little different."

Jorge: Hah-hah-ha-ha-ha.

Jorge: Was it really that bad?

I mean, "different"?

We'll see.

Kevin: Currently, we have quite a few parts in there that's curing.

That's in primer.

This is the primer phase.

Jorge: Right, how long will it take to cure?

Kevin: For primer, it takes two hours.

Jorge: Oh, okay, that's not bad.

Kevin: For a top coat, we're runnin' three hours to four hours for top coat.

This is, like, our prep area where we sand it, getting everything ready to go in for topcoat.

So, like, now we have another wing.

The aileron-- Jorge: This is already primered?

Kevin: That's already primered.

Jorge: And cured?

Kevin: Yes.

Those are our rotisseries.

Jorge: Rotisseries?

So, like chicken, turkeys and-- Kevin: Similar.

Jorge: Similar?

Okay.

Kevin: But we put our aircraft in the rotisserie.

Jorge: Does it turn?

Kevin: It turns.

It doesn't rotate one-- all the way, 360-- Jorge: Okay.

Kevin: --but it does go from side to side.

Jorge: You could rotisserie a dinosaur then.

Kevin: That's correct.

So this is what we use to take the aircraft through bodywork, through painting, priming.

It goes-- Jorge: This is where the top coat, it all happens, and then you heat it up?

Kevin: That's correct.

Jorge: So the painting is not in the oven over there?

Kevin: Yeah, the final painting is done in there.

Jorge: Oh, it is?

Kevin: No painting done outside of that booth.

So what happens is we take the fuselage skin, and we plug it in, basically, and then we have the aircraft lifted, and then we do all of our body work and painting on this fixture.

Jorge: What was it you said?

There's no painting outside of that place?

Kevin: There's no painting.

Jorge: So what about-- Kevin: But this whole fixture goes inside.

Jorge: Ohhh, hah-hah, okay.

Kevin: The whole thing.

Jorge: Gotcha.

Jorge: So now that I know how the plane was being built, I wanna get my hands on it, but I need some quick instructions and a little bit of prepping.

Jorge: Okay, Kevin, from what I know is you put the sauce, right?

You put a little bit of the sauce.

Kevin: Mm-hmm, not too much sauce.

Jorge: Too much sauce.

Too much sauce.

Can I still do it with it?

Kevin: Yes, just set the buffer flat.

Don't pull the trigger.

Just set it flat.

Move it from left to right.

Mm-hmm, now pull the trigger.

Jorge: So although it was fun to do my part, it was obviously nothing compared to what these highly skilled workers do, day to day, day in, day out, specialized work done by many workers with specialized training.

Jorge: Is it a leisure plane?

Kevin: It is a leisure-- Jorge: It is, right?

Kevin: Yeah, I mean, but it's-- Jorge: Is it something people can travel, or is it just, if you're in a lake, that's gonna be your playground?

Kevin: Yeah, you can do both.

We've flown different places.

Our aircraft, as far as flight time-- Jorge: You know that-- your distance?

Kevin: Correct.

Jorge: You know what your reach is?

Kevin: Correct.

Jorge: So, if it's within that, you could travel.

Kevin: You could, yeah.

Jorge: We were almost ready to see the final result of the final product, but, first, all the electrical parts have to be assembled.

Kevin: So this is our final assembly.

Jorge: Oh, my goodness.

Kevin: So this is actually a finished aircraft.

Jorge: Wow.

Wow, this is so cool.

I still have one question.

Kevin: Yep.

Jorge: Can you make it in black?

Kevin: Well, here's the thing.

We would love to, but we don't wanna heat up the adhesive.

Jorge: Yeah, heh-heh-ha-ha.

Well, I think it's something Bruce Wayne would ask you.

Kevin: That's true.

That's true.

Batman.

It'd be a great feature.

It'd be fantastic.

Jorge: Okay, so the A5 doesn't come in my preferred Batman black.

It's an amazing piece of technology though.

It even has this remarkable feature which makes it possible to fold the wings for transporting.

And just look at this: They really thought of everything when making this plane.

Kevin: This just gives us the ability to tow the aircraft and also use our trailer.

So it retracts.

We push it in.

We seat it on the stud.

Jorge: Yeah, and just one person's doing it so-- Kevin: And one person.

Jorge: Just like that, huh?

Kevin: That's it.

Jorge: What kind of profile, capacity-wise, does the buyer need to have, you know, like, a pilot's license to see-- or do you--and that's not your-- that's not your thing?

Kevin: No, we actually trained.

For example, we'll train you-- Jorge: Really?

Kevin: --before you attempt the aircraft.

Jorge: Do you have a simulator here?

Kevin: We don't have a simulator.

Jorge: Darn-- I was like-- Yeaaaah.

Kevin: We have some really good pilots, really good sales team that will get you an aircraft, take you on a flight, give you-- Jorge: Where?

So you'll train people who have never flown before?

Kevin: That's correct.

Jorge: After a quick introduction on the autopilot, I was ready to board the aircraft and take it for a spin myself.

Just kidding, folks.

I'm not taking this anywhere.

I feel like a little boy's dream was coming true.

This was an easy thing to geek out for.

Gauges, buttons, lights, radars, I'm ready.

Jorge: Kevin, can I sit on the cockpit on this?

Kevin: Yes, you can take a seat.

Jorge: "Take a seat, young Anakin," hah-hah-ha-ha-ha.

Oh, boy.

I don't wanna mess it up, so tell me-- Kevin: So step here.

Jorge: Okay.

Kevin: Grab there.

Step up.

Jorge: And grab here.

Kevin: Yep.

Jorge: Woo, is it a two-pilot or-- Kevin: Yes, you can--either side can be controlled.

Jorge: But do both need-- do you need two pilots?

Kevin: Uh-uh.

Jorge: Okay.

Kevin: No, no.

Jorge: Oh, man, this is the first time.

"Rogue One, Rogue One, Ghost Rider.

This is Voodoo One.

Mustang, arriving, bearing two knots.

You got your horizon, right?

Air speed, altitude.

Oh, come on, we need a gas station.

What's up with that?

We're makin' a run for it.

Strap in, Kevin.

Where we're going, we don't need roads.

Kevin: That's true.

I prefer--you know, Cancun or somethin' would be nice.

Jorge: Cancun, it is, my friend.

Course plotted.

Ready to go.

Kevin: And then we can fly with the windows out 'cause we do anyway.

Jorge: Do you do that?

Kevin: Mm-hmm.

Jorge: Oh, really.

Oh, man.

So, wait a second: If you do it with the windows open, what about any water splashing?

Is this gear, like, okay?

Kevin: Yeah, so we have a bilge pump inside, so soon as the water comes in, we get an indicator, and then we just turn on the bilge pump, and it starts pumpin' out the water.

Jorge: So then none of these gauges short-circuit or anything?

Kevin: No.

Jorge: Oh, wow.

Kevin: 'Cause the way the aircraft is created, everything will go to the back.

Jorge: This has to be a fun thing to ride.

There's probably things that it cannot do, one of which, I'm just guessing, you probably can't go-- you know, flip over, right?

Kevin: No, no.

Jorge: There's limitations that is has?

Kevin: That's correct.

That's right.

But we do have an amazing safety feature which is the parachute.

Jorge: No way.

You see, that alone would make me consider-- Kevin: So, if you get in some trouble, then just pull the chute.

Jorge: How rough of a landing is it with a parachute?

Kevin: So, luckily, we haven't had a reason to use the parachute, which is great for us, but I'm assuming it would be very-- Jorge: Yeah?

Kevin: Yeah.

Jorge: Okay, 'cause you guys have probably tested it, you know, probably tested it.

So, you know, even with a parachute, you gotta--it's still an emergency situation.

Kevin: That's correct.

Jorge: I mean, it'd be unreasonable to think you're gonna come down like a feather, you know, and just, like, "Ahhh."

Kevin: Mm-hmm.

Jorge: Like, I mean, there's gotta be a degree of a, you know, a little bit of a bump.

Kevin: Yeah, for sure, for sure.

Jorge: But, yeah, if they tested it, I imagine, it's safe enough.

Oh, oh, I'm gonna call you guys: "You know what?

The landing wasn't like--" Kevin: "The landing wasn't smooth," but, yeah, it is what it is.

Jorge: "It wasn't like landing on a pillow," you know?

No, no, "I'm alive, and thank you for putting that feature."

Kevin: Yes, yeah.

Jorge: Before coming to this incredible facility, I didn't even know this type of aircraft existed.

Now I go home, knowing that engineers have come a long way and that we still haven't reached our maximum capacity.

The ICON A5 amazed me, and if it didn't cost more than a single family home in Texas, I'd consider purchasing one for myself, as scared as I am of flying.

Jorge: Pretty cool thing they got going.

Pretty good operation you got going here, my dude.

Kevin: Thank you.

Jorge: Let's see if we can use the instructions-- "Flaps are up."

Flaps-- Kevin: Right, flaps are good.

Landing gear down.

Jorge: So after taking a tour of this factory for big-boy toys and learning how the composite-manufacturing process works, we look forward to taking flight on more adventures the next time we cross south.

male voice: November 557 Bravo Alpha cleared for takeoff.

♪♪♪ male announcer: Like to know more about the places you've just seen?

Maps, videos, podcasts, and more, at CrossingSouth.com.

We also do Facebook, Instagram, and YouTube.

♪♪♪