Robotic GTAW may prove key to higher gas turbine engine production

Abstract

When Pratt and Whitney began examining areas for improvements in its manufacturing processes, it took a long look at its welding operations. Because it was committed to increasing its industrial base, improving productivity and reducing parts costs through facilities modernization and implementation of new technologies, the company performed a comprehensive analysis to identify projects to help it achieve these goals. The company`s analysis included the following: (1) review of all manufacturing operations and the identification of high-cost and problem areas associated with welding; (2) determination of the root causes of performance variations and rework; (3) identification of applicable technologies that could be used to solve the problems; and (4) review of associated cost areas (materials, tooling, etc.) for potential improvements. The areas identified as needing improvements included the following: (1) manual GTA welding operations; (2) welding process control; (3) time-consuming postweld inspections; and (4) excessive x-ray film usage. Also conducted were business, management and economic analyses that considered cash flow, payback period and savings to investment ratios. A technical risk assessment was completed to ensure that the technical requirements for the project were reasonable and compatible with the company`s long-term manufacturing strategies.