GE Aerospace’s lean production initiative has led to significant improvements in its jet engine repair operations, company officials say — helping keep more aircraft in service.
Maintaining LEAP Engines
The lean operating model, known as Flight Deck, sought to enable the company’s network of global “On Wing Support” repair hubs to increase its efficiency — particularly as production of the LEAP turbofan engine grew to unprecedented levels.
The LEAP, made by the GE Aerospace and Safran joint venture CFM International, is made at the fastest rate ever for a commercial turbofan engine, officials say.
Redesigning Turbine, Combustor Repairs
One of the common repair procedures for the LEAP engine is known as a high-pressure turbine refresh, in which the engine’s turbine parts and combustor are either refurbished or replaced.
In mid-2023, workers from the seven OWS facilities gathered with company leadership and technical staff for a multi-day “kaizen” event in a bid to redesign that particular procedure.
Fixing Dozens More Engines
The exercise, GE Aerospace officials said, led to a 170% jump in repair capacity by the final quarter of 2024. That equates to repairs on more than 40 engines that would have otherwise had to wait.
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