Lean transformation and relocation of jet engine assembly operations

Abstract

As part of continuing lean transformation efforts at Pratt & Whitney, the Middletown Engine Center has turned its focus on the GP7000 turbofan engine as a target for lean implementation. Projected increases in GP7000 production volume over the next few years, along with aggressive cost reduction targets, are driving the current push to optimize GP7000 assembly and test operations. The internship work described in this thesis was sponsored to achieve three primary objectives: (1) Identify and then implement opportunities to reduce waste and increase productivity for GP7000 assembly and test, (2) determine an optimal configuration for restructuring GP7000 assembly and test operations and create a business case demonstrating the value of the proposed configuration, and (3) organize an implementation team and begin execution of a GP7000 strategy. This thesis details an approach for lean transformation of assembly and test operations in an aerospace company. Additionally, the thesis provides a framework for making difficult relocation decisions and shows how lean transformation can be part of an assembly relocation strategy. As a direct result of this work a lean transformation and relocation strategy is in place for the GP7000 and the implementation of that strategy was underway at the conclusion of the internship. The thesis also describes a comprehensive risk management plan that employs the Operational Risk Management (ORM) process from the U.S. Air Force together with a phased implementation approach.