With the increasing demand for the CFM International LEAP engine—a product of a joint venture between GE Aerospace and Safran Aircraft Engines—OWS has adopted cutting-edge solutions to optimize its repair processes. Central to this effort is FLIGHT DECK, GE Aerospace’s proprietary lean operating model, designed to drive continuous improvement and efficiency.

Streamlining High-Pressure Turbine (HPT) Repairs

A key focus for OWS has been improving the high-pressure turbine (HPT) refresh, a common repair that involves refurbishing or replacing combustor and turbine components. In June 2023, a global team of OWS technicians and leaders gathered for a kaizen event, an intensive multi-day workshop aimed at eliminating inefficiencies and standardising procedures.

By transitioning from a fixed-bay repair method to a flow-based system, OWS nearly doubled its capacity. Repairs that once took 40–60 days have been streamlined by removing repaired components and placing the remaining engine in storage to free up space for the next job. This approach boosted capacity by 170%, enabling the servicing of 41 additional engines by the end of 2024.

“We focused on achieving flow — ensuring work proceeds continuously and efficiently,” explained Jonathan Hill, Senior FLIGHT DECK Operations Leader at CFM Programs. “Eliminating waiting time and optimising our footprint were key drivers of success.”

A Culture of Safety and Standardisation

Throughout the process, safety remained paramount. The kaizen events identified and implemented 60 safety and quality improvements, ensuring technicians work in secure environments. These changes, disseminated across all sites, reaffirm GE Aerospace’s commitment to a safe and efficient workplace.

The events also resulted in a standardised procedure for HPT refreshes across all OWS facilities. “This global standard allows us to share knowledge and improvements quickly, ensuring consistent results across our network,” said Alex Henderson, General Manager for OWS at GE Aerospace.

Continuous Improvement for the Future

The FLIGHT DECK model’s emphasis on continuous improvement has created a momentum that extends beyond the initial kaizen event. “Every kaizen strengthens the process, empowering more people to drive change,” said Andy Nader, OWS’s Global Delivery Leader.

As the demand for LEAP engines continues to rise, GE Aerospace’s refined processes position OWS to meet customer needs effectively. “Every customer appreciates faster turnaround times and high-quality repairs,” added Henderson. “We’ve identified additional areas for improvement, ensuring we stay ahead of the curve.”

With innovation at its core, GE Aerospace’s OWS team is setting a new benchmark for engine repair efficiency, reinforcing its position as a trusted partner for airlines worldwide.