SINGAPORE, Feb 13 (GeokHub) — GE Aerospace is accelerating automation and lean manufacturing practices at its Singapore repair hub as the aviation industry grapples with severe jet engine maintenance bottlenecks.
At the center of this transformation is a new automation lab where experienced technicians are training robotic systems to replicate delicate repair tasks once performed entirely by hand — part of a broader push to increase repair capacity without expanding factory space.
Aviation’s Repair Backlog Crisis
Unexpected wear in newer-generation jet engines across the industry has grounded aircraft and extended maintenance queues to months. Airlines have been forced to keep older aircraft flying longer, intensifying demand for repairs and spare parts.
The strain has fueled tensions between airlines and engine manufacturers. Carriers argue that supply shortages have driven higher costs, while manufacturers say they are investing heavily to expand service support after significant research and development spending.
Industry players including Pratt & Whitney are also balancing the dual challenge of supplying new aircraft assembly lines while maintaining the existing global fleet.
Singapore as a Strategic Hub
GE’s 2,000-employee Singapore facility is undergoing upgrades that could total up to $300 million in investment. The goal: increase repair volume by roughly 33% without increasing the plant’s physical footprint.
The strategy involves reorganizing production lines, redesigning floor layouts, and embedding automation and AI-driven monitoring tools.
The initiative forms part of GE’s “Flight Deck” system — its adaptation of lean manufacturing principles focused on eliminating waste and improving efficiency through continuous improvement.
Faster Turnaround, Lower Costs
One major focus is accelerating repairs of high-temperature turbine components from the widely used CFM56 engine platform. Turnaround times in one section have improved from around 40 days in 2021, with a long-term target of reducing that to 21 days by 2028.
Repairing used parts rather than replacing them with newly manufactured components can significantly reduce costs for airlines and ease pressure on limited parts inventories. According to company estimates, certain repair processes can cut both turnaround time and costs roughly in half.
Teaching Robots Precision Skills
Among the most complex tasks being automated is “blending” — reshaping worn compressor blades to meet strict tolerances measured in thousandths of an inch.
Previously performed entirely by skilled technicians, this intricate process depends on precision, tactile feedback, and visual judgment. GE is now working to capture that expertise in robotic workflows that can deliver consistent results at scale.
If successful, the approach could reduce reliance on scarce specialized labor while boosting throughput and consistency.
Repair Economics and Industry Outlook
Maintenance and repair services represent one of the most profitable segments of the jet engine business. Manufacturers also license specific repair procedures to third-party shops, creating additional revenue streams.
However, scaling repair capacity is constrained by strict safety approvals and quality control requirements. Analysts note that while repair demand surged during slower new aircraft production cycles, that dynamic may begin to normalize as manufacturing stabilizes.
Still, airline executives caution that supply chain pressures are unlikely to disappear quickly.
GE’s automation and lean overhaul in Singapore could provide a blueprint for the broader aerospace industry — shifting from reactive crisis management toward sustained operational efficiency.
