GE Aerospace Singapore Automation Tackles Repair Backlogs
GE Aerospace Singapore automation efforts are accelerating as the company upgrades its 2,000-employee repair hub to address one of aviation’s biggest constraints: overloaded maintenance shops and scarce replacement parts. Technician Suresh Sinnaiyan, who has spent more than a decade manually repairing jet-engine compressor blades, is now helping teach robots to replicate the same delicate sanding and blending techniques at the company’s new automation lab.
Unexpected wear and tear in next-generation jet engines across the industry has grounded aircraft and forced airlines to extend the use of older planes. That has stretched engine repair queues into months. Airlines have publicly criticised manufacturers for rising maintenance costs, while engine makers argue they are investing heavily to expand support capacity after absorbing significant development expenses.
Investment and Lean Manufacturing Strategy
GE Aerospace Singapore automation upgrades form part of a broader investment plan that could total up to $300 million. The company aims to increase repair volume in Singapore by 33% without expanding the physical footprint of the facility. Instead, it is reorganising workflows, redesigning floor layouts, and introducing robotics, digital tracking tools and AI systems.
The plant is also rolling out “Flight Deck,” GE’s version of lean manufacturing principles focused on eliminating inefficiencies and improving consistency. The strategy seeks to replace reactive problem-solving with steady, incremental gains in productivity.
Faster Turnaround, Lower Costs
Repairing used parts instead of replacing them with newly manufactured components can significantly ease supply pressure. GE says advanced repair techniques can halve both processing time and airline costs. In one section overhauling CFM56 turbine nozzles, turnaround time has improved from 40 days in 2021, with a target of 21 days by 2028.
The facility is simultaneously preparing to service newer LEAP engines as they begin entering overhaul cycles, ensuring airlines are not forced to rely on scarce and costly new components.
Teaching Robots Precision Skills
One of the most complex tasks under GE Aerospace Singapore automation involves compressor blade blending — a process historically performed entirely by hand. Each blade must be restored to within a few thousandths of an inch, relying on tactile skill developed over years.
By translating that craftsmanship into a repeatable robotic process, GE hopes to reduce reliance on scarce specialised labour while boosting throughput. However, strict regulatory approvals and quality controls limit how quickly such automation can scale.
Industry analysts caution that while automation can ease repair bottlenecks, broader supply constraints may take time to resolve. Still, if successful, GE Aerospace Singapore automation could help airlines reduce downtime, stabilise costs and gradually relieve pressure across global aviation maintenance networks.