Revolutionizing Engine Maintenance: GE Aerospace's OWS Shanghai Site Thrives with FLIGHT DECK Efficiency

GE Aerospace's On Wing Support (OWS) Shanghai facility uses FLIGHT DECK, a proprietary lean operating model, to improve maintenance efficiency. The site has a moving repair line where engines glide smoothly through the production line for repair and maintenance. This innovation has brought about big gains in efficiency and reduced turnaround time. The traditional model had engines remain stationary at fixed workstations, leading to supply chain disruptions and extended turnaround times. The FLIGHT DECK model has improved maintenance efficiency and reduced turnaround time by 47%.

GE Aerospace's On Wing Support (OWS) facility in Shanghai has implemented a groundbreaking approach to engine maintenance, significantly enhancing efficiency and reducing turnaround times. The innovative FLIGHT DECK model, a proprietary lean operating system, has transformed the traditional maintenance process by introducing a moving repair line. This innovative method allows engines to glide smoothly through the production line, improving overall maintenance efficiency.

The traditional model involved engines remaining stationary at fixed workstations, similar to car servicing at a dealership. However, this approach led to supply chain disruptions and extended turnaround times. In the first quarter of 2025, the Shanghai OWS facility faced a backlog of engines awaiting repair, with others parked for service, ultimately failing to meet projected targets.

In response, the Shanghai OWS team adopted a "flow line" approach, moving engines through distinct stages: disassembly, module repair, and reassembly. This shift was supported by the introduction of heijunka, a buffer storage solution that optimizes floor space and holds disassembled engines while awaiting parts. This approach allowed the team to disassemble up to 10 engines and store them until overseas-repaired parts arrived, enabling swift module repair and minimizing delays.

The implementation of FLIGHT DECK has resulted in a 47% reduction in turnaround time. Since its activation in 2024, the Shanghai OWS facility has seen a significant increase in engine throughput, with deliveries soaring from one engine in the first quarter to nine in the second quarter. The new process has also transformed the workforce, with technicians focusing on specific phases and freeing up resources to enhance airline customer support.

The success of the Shanghai flow line model has led to its adoption by the Cincinnati OWS facility, with Wang Tao, the Shanghai OWS site leader, set to visit the Seoul OWS site to discuss new plant standards. GE Aerospace is committed to continuous improvement through FLIGHT DECK, creating greater value for customers and ensuring safety, quality, delivery, and cost (SQDC) [1].

References:
[1] https://www.geaerospace.com/news/articles/let-it-flow-ows-shanghai-site-soars-flight-deck
[2] https://www.marketbeat.com/instant-alerts/filing-scotia-capital-inc-buys-6001-shares-of-ge-aerospace-nysege-2025-08-04/