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Pratt & Whitney Halves Engine Assembly Time Through Automation

Pratt & Whitney Halves Engine Assembly Time Through Automation at Singapore Facility
Pratt & Whitney’s Eagle Services Asia engine centre in Singapore has significantly reduced the assembly time for high-pressure compressor (HPC) rotors used in the GTF PW1100G-JM engine through the implementation of advanced automation. The introduction of a robotic system named Alfred has cut the assembly process from 14 hours to just seven, allowing skilled technicians to focus on more complex tasks and marking a substantial improvement in operational efficiency.
Automation Enhances Efficiency and Safety
Alfred, specifically designed for assembling HPC rotors for the Airbus A320neo family, operates in double shifts beginning at 7:30 am. The robot undertakes repetitive and potentially hazardous tasks such as placing rotors in an industrial oven, cooling them, and transferring components to a hydraulic stacking system with high precision and consistency. Gilbert Sim, director of aftermarket operations, core and technology transformation at Pratt & Whitney, described Alfred as “built for pressure,” highlighting the robot’s ability to maintain performance under demanding conditions.
This automation initiative forms part of Pratt & Whitney’s broader commitment to Industry 4.0 technologies, encompassing automation, connectivity, and data analytics. These innovations are being progressively integrated across the company’s maintenance, repair, and overhaul (MRO) facilities worldwide. Sim emphasized that these technologies are rapidly enhancing MRO performance and driving efficiencies across the shop floor.
The concept for Alfred originated from a technician’s ambition to accelerate the traditionally lengthy HPC module assembly process. Leveraging best practices from Pratt & Whitney’s production lines and RTX’s Core operating system, the Eagle Services Asia team transitioned from concept in 2021 to a fully operational automated cell by 2023, completing the development in just two and a half years.
Operational Impact and Industry Response
Alfred’s workflow begins when an operator loads hardware into the cell. With a single button press, the robot assumes control, swapping tools and handling parts that pose risks of burns or injury to human workers. The robot heats each component to expand materials for tight fits and then moves them to the hydraulic stacking system, which assembles the front hub, eight rotors, and rear hub. Sim likened the assembly process to “a Lego process,” underscoring its precision and modularity.
The automation has yielded multiple benefits, including safer operations with reduced injury risk, enhanced repeatability and reliability that minimize rework, shorter process times, and decreased waste. Custom fixtures integrating software and hardware have also helped minimize the system’s physical footprint.
While the gains in speed and efficiency are clear, Pratt & Whitney remains vigilant regarding quality control and the long-term reliability of the assembled engines as automation expands across its operations. The company is closely monitoring these factors to ensure sustained performance standards.
The market has responded positively to these advancements. Airbus CEO Guillaume Faury recently acknowledged Pratt & Whitney’s improved delivery pace as a key factor in meeting aircraft production targets, reflecting growing confidence in the company’s ability to fulfill orders on schedule. Meanwhile, competitors such as GE Aerospace are accelerating their own development efforts, with the XA201 engine for the U.S. Air Force’s Next Generation Adaptive Propulsion program aiming to match Pratt & Whitney’s strides in automation and efficiency.
Alfred represents the latest step in Pratt & Whitney’s ongoing automation initiatives, signaling a broader transformation in aerospace manufacturing and maintenance as the industry seeks to balance speed, safety, and reliability in an increasingly competitive environment.

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