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Transforming Maintenance, Repair, and Overhaul Operations

Transforming Maintenance, Repair, and Overhaul Operations
At Collins Aerospace’s Maintenance, Repair, and Overhaul (MRO) facility in Singapore, advanced automation technologies are revolutionizing inspection processes. The facility’s proprietary Automated Vision Inspection (AVI) System employs sophisticated robotics combined with optical character recognition technology, similar to QR code scanning, to reduce inspection times dramatically—from one hour to just a few minutes. This versatile system is capable of handling a broad spectrum of components, ranging from generators to inventory kits, illustrating how Collins Aerospace, a subsidiary of Raytheon Technologies, is actively integrating Industry 4.0 principles to modernize its operations.
Innovations in Inspection and Data Management
Daven Tey, regional director for Aftermarket Operations in Asia-Pacific, emphasized the company’s commitment to evolving Industry 4.0 concepts to meet the complex demands of aerospace MRO. He noted that as these technologies have become more accessible and customizable, Collins Aerospace has pursued innovative solutions that are now materializing on the shop floor. The AVI system employs machine vision technology to capture detailed images of components such as jet-engine nacelles, comparing them against “golden images” that represent ideal conditions. Mounted on the articulating arms of autonomous robots, the cameras can reach difficult areas, ensuring inspections are both precise and consistent. For example, when examining the 159 items in a Quick Exchange Kit, the robot captures 56 standardized photographs and analyzes them with greater speed and accuracy than traditional manual inspections.
In addition to robotics, the Singapore facility has developed a Digital Operating System (DOS) that records job data in real time at every repair station. This system provides immediate access to live data for the entire team, enhancing communication, preventing issues, and reducing waste. The DOS proved particularly valuable during the COVID-19 pandemic by enabling seamless digital connectivity between the Singapore and China MRO sites. Lee Theng Liang, director for Aerostructures Operations, highlighted that the DOS amplifies site efficiencies by facilitating real-time problem resolution through electronic “management-by-walking-around” meetings conducted across multiple locations.
Industry Challenges and Competitive Responses
Despite these advancements, transforming MRO operations presents significant challenges. Substantial investments in new technologies and processes are necessary, alongside the need to comply with evolving regulatory standards. The industry also faces a growing skills gap within the workforce. Meanwhile, market demand for sophisticated MRO services continues to rise, driven by the pursuit of cost efficiency and sustainability.
In response, competitors are forging strategic partnerships and investing in workforce development. Kenya Airways, for example, has partnered with Qatar Airways to share MRO services and expertise. Similarly, companies such as BEP Surface Technologies are refurbishing manufacturing facilities and launching employee development programs aimed at addressing skills shortages and future-proofing their operations.
As Collins Aerospace and its industry peers advance these innovations, the integration of intelligent technologies and digital systems is establishing new benchmarks for efficiency, accuracy, and collaboration within the MRO sector, signaling a transformative era for industrial maintenance and repair.

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