GE Aerospace Uses Robots and Lean Methods to Speed Up Jet Engine Repairs

Post by : Saif

Jet engine repair is a critical part of keeping airplanes flying safely. But in recent years, airlines around the world have faced long waits for engine repairs due to high demand and limited parts. GE Aerospace, a leading aircraft engine maker, is now turning to robots and new management methods to tackle this problem.

In Singapore, GE Aerospace’s repair hub is experimenting with automation and “Lean” techniques, inspired by Japanese car manufacturers. The goal is to increase repair capacity without expanding the factory space. Robots are being taught to handle precise tasks that were once done only by skilled technicians. For example, compressor blades, which must be shaped very accurately, are now being repaired with robotic help. A technician guides the robot to mimic his touch, allowing the machine to perform delicate work safely and efficiently.

The company plans to invest up to $300 million to improve its Singapore hub. This includes reorganizing workspaces, using digital tools, and automating repetitive tasks. GE’s CEO Larry Culp explains that this approach focuses on improving every day and every hour rather than rushing at the end of the quarter. The result is faster repairs and lower costs for airlines.

Repairing existing parts can reduce pressure on new parts, which are expensive and sometimes hard to get. For example, CFM56 turbine nozzles, which endure extreme heat, used to take 40 days to repair. GE is reorganizing the workspace and expects to reduce this to 21 days by 2028. At the same time, space is being prepared for the newer LEAP engines, which are starting to need repairs.

One of the hardest parts of this work is capturing the skill of technicians in a robot. Shaping a jet engine’s compressor blade requires extreme precision, often to within a few thousandths of an inch. By teaching robots to replicate this skill, GE hopes to reduce dependence on a limited workforce and increase efficiency.

The move also reflects a bigger trend in aviation. Engine makers earn large profits from servicing used parts and licensing repairs. Improving repair speed and quality benefits both airlines and manufacturers. However, the industry warns that the global shortage of parts and skilled workers will not disappear quickly.

By combining automation, Lean methods, and skilled human guidance, GE Aerospace is trying to transform jet engine repairs. This change promises faster turnarounds, lower costs, and more efficient use of resources. Airlines and passengers may eventually see the benefits in the form of smoother operations and possibly lower fares.

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