Spirit Aero Systems, Prestwick

Spirit Aero Systems is one of the world’s largest manufacturers of aerostructures for commercial airplanes, defence platforms, and business jets. At Prestwick, Spirit’s Scottish arm of the organisation, they manufacture wings and wing parts for both Boeing and Airbus and are an integral part of Spirits success.

With a workforce of over 1000 Kylemark has successfully been providing the uniform to Spirit Prestwick for a number of years now with the hope this will continue for many more.

 

The Brief

Kylemark were to supply the full uniform. Polo shirts, t-shirts, shirts, work trousers, sweatshirts, jackets and much more. One of the factors was to give their employees choice whether in the hangers or the office, but still keeping a coherent look across the entire multi location site.

Every garment is either embroidered, printed or tax tabbed and is supplied to the company in individual wearer packs making for easy distribution.

The Process
The ethos of Kylemark is to give the best service we can. To make the whole uniform ordering process as simple and stress free as possible for our customers. So, when you're supplying a complete uniform roll out to a company the size of Spirit, organisation is the key.

In this case Spirit knew exactly what type of garments they wanted and the budget for each employee. Kylemark then put together uniform to fit in to these conditions, stipulating what type and where the branding was to be placed. Once this was settled physical garments were sent for scrutiny before the final sign off.

Normally when this happens a sizing pack is sent out to the client to give their employees a chance to try the new uniform on but as Spirit is so local to Kylemark we implemented two sizing days where the factory could come and try on the new garments.

The Ordering
Kylemark supplies personalised online ordering portals for many of our customers. Spirit is no different. Each employee gets their own login where they can go on to the website and order their uniform allocation. This makes it easy for providing individual wearer packs especially when there are over 1000 employees.

 

The Production
This job was now passed to our factory floor where the embroidery, print and tax tabbing takes place. Everything is produced in-house so we have complete control over quality. As you can expect there are thousands of garments to be branded, so again, organisation is key. It doesn't take long for our time served operators to get into their stride. Kylemark are continually updating to the newest technology to help make production as smooth and efficient as possible.

The Future
Well, we must have done something right as Spirit's sister factory in Belfast has now come on board. Now we regularly see pallets leaving the warehouse to their 1100 staff in Ireland. As you can see, Kylemark has plenty of experience dealing with large uniform roll outs for 1000 staff and over and our team are becoming somewhat experts in this.

Case Study Update:

Supporting the Transition to Prestwick AeroSystems

Following the acquisition of the Prestwick facility by Airbus, the site transitioned from Spirit AeroSystems to Prestwick AeroSystems in 2026.

Having supplied the business for a number of years, Kylemark was retained to manage the complete uniform rebrand across more than 1,200 employees — under particularly tight turnaround times.

The Challenge

The rebrand required:

  • Digitisation and approval of the new Prestwick AeroSystems logo
  • Rebranding across multiple garment types and departments
  • Coordinated distribution to 1200+ employees
  • Delivery within a compressed timescale
  • Zero disruption to operational output

 

This was not simply a logo swap — it was a full, structured uniform transition at scale.

 

To ensure accurate garment allocation and reduce post-issue exchanges, Kylemark hosted a dedicated three-day sizing range at Prestwick AeroSystems.

Employees were able to:

  • Try on garments in person
  • Confirm fit across multiple styles
  • Receive guidance on sizing and garment suitability

 

This significantly reduced errors and streamlined the rollout phase.

Dedicated Online Ordering Portal

Alongside the sizing event, we built and managed a dedicated online uniform portal tailored specifically for Prestwick AeroSystems.

The portal allowed:

  • Controlled garment selection by role/department
  • Pre-approved branding placement
  • Individual employee ordering
  • Centralised tracking and reporting

 

This ensured consistency, accountability and administrative efficiency during the transition.

Structured Production & Rollout

With tight deadlines in place, production was carefully batched and prioritised to align with the rebrand schedule.

Over 1,200 employees were issued newly branded uniforms, professionally embroidered and delivered in a coordinated rollout plan.

The Result

The transition from Spirit AeroSystems to Prestwick AeroSystems was completed within the required timeframe and without disruption to daily operations.

By combining on-site sizing, digital ordering infrastructure and managed production scheduling, Kylemark delivered a smooth and controlled rebrand at enterprise scale.

Kylemark continues to support Prestwick AeroSystems with ongoing uniform supply, replenishment and branding services.

 

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