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FOCUS - GE Aerospace uses robots and a 'Lean" approach to solve jet engine repair crunch

Suresh Sinaiyan, a GE Aerospace technician, has spent over a decade repairing compressor blades on jet engines by guiding them with precision across a sanding band.

At the new automation lab of?the aerospace company in Singapore, he teaches a robot how to do the exact same thing.

The switch is part GE's effort to prepare 'the next wave of Industrial Development' and ease a 'aviation's most significant bottleneck: overloaded repair workshops and scarce parts.

The industry's newest jet engines are prone to unexpected wear and tear, which has caused many airlines to idle older jets for longer and stretched maintenance lines.

This pressure has now become a public battle. The airlines have complained about engine makers raising prices to take advantage of shortages, while the manufacturers claim they are investing money in expanding support because they incurred huge development costs.

Tony Fernandes is the co-founder and CEO of Malaysian low cost airline AirAsia. He said it bluntly: "They must remember that airlines are their future, so treat us as partners."

SINGAPORE as the Pressure Valve

GE claims that Singapore is a critical part of its solution.

The company is upgrading its 2,000-employee service center with digital tools, AI and more automation as part of a $300 million investment plan.

The company wants to increase repair volume by?33% in Singapore without expanding the footprint of the site -- by reorganising, reshaping and automating tasks when it's efficient.

The factory is leading the way in GE's "Flight Deck" recipe for continuous improvement, eliminating waste and reducing costs. This was pioneered by Japanese automakers and promoted by CEO Larry Culp.

It's not about sprinting to the end of a quarter in order to produce a Wall Street Guide. Culp said in an interview that it is about making every minute and day count.

GE, along with rivals like Pratt & Whitney, has been trying to find a balance between supplying new-airplane assembly line engines and parts and keeping the fleet flying.

By repairing more worn parts, you can reduce the pressure on your engine by reducing the need for replacements with new components.

GE claims that repairs can halve 'the time required for key processes and also halve costs to airlines.

Faster turns, tighter floor space

Iain Rodger of GE Aerospace Component Repair Singapore told me during a tour that "repair can improve turnaround times... the shorter the time the engine has to be off the wing the better."

A reorganized repair area is overhauling CFM56 turbo nozzles that have been scorched by extreme heat in one of the most popular engines on earth.

Workers claim that turnaround times have improved since 2021 when they were 40 days. GE targets 21 days by the year 2028.

The area will lose about a third its floor space in order to meet the next challenge, which is to develop repair capabilities for newer LEAP engine models that are starting to enter overhaul cycles.

If the airline does not approve repairs, it may be forced to replace worn out parts with newer, more expensive, and limited-supply replacements.

Han Hui Min, Nozzles' Business Leader, said of the new layout: "Now we can identify issues and see where they are."

TEACHING ROBOTS the HUMAN TOUCH

Repairs that require a technician to touch them are among the most difficult?to automate.

Take these compressor blades out of a CFM56 motor.

The spinning blades squeezing the air as it rushes in the engine core create pressure. After years of use, the blade?tips will deform. This must be repaired by a process known as blending.

It's really difficult to do. Sinnaiyan said that (until now) the process was 100% manual. The blades must be filed down to a few thousandths, using eye, feel and coordination.

GE is betting that if they can capture this skill and turn it into a robotic process that can be repeated, then it will reduce the need for specialized labour at a lower cost.

Analysts have noted that engine manufacturers make some of their largest profits by servicing used parts, and licensing certain repairs to shops in exchange for lucrative royalties.

The process of each repair is the "secret sauce" for an increasingly important part of the business.

Scaling repairs have limits. The work must adhere to approved procedures and strict standards of quality.

Nick Cunningham, an analyst at Agency Partners, said that the slowdown in plane production - which increased demand for older jets and subsequently for repairs – is nearing its end.

If GE's Singapore changes are successful, they can help the industry overcome its bottlenecks. They could also ease fares.

Airlines executives and others have warned that the supply crunch is not likely to disappear quickly.

Culp explained that the goal was to move away from heroics and firefighting, in favor of a more preferred type of performance. Reporting by Tim Hepher and Rajesh K Singh in Singapore; Editing and production by Joe Brock, Matthew Lewis

(source: Reuters)