Selected Engineering Impact – Case Studies
Across roles at Rolls-Royce and Airbus, I have repeatedly identified and resolved manufacturing and process constraints affecting production efficiency, quality, and delivery timelines. My approach focuses on simplifying complex systems, developing practical engineering solutions, and implementing improvements directly within production environments.
Case Study 1 – Engine Component Measurement Breakthrough
Organisation: Rolls-Royce
A dimensional inspection issue prevented certain engine components from being measured correctly. As a result, parts were being scrapped and engine builds were delayed. The issue had existed for approximately two decades.
I developed a new inspection approach that allowed the components to be measured using existing equipment and approved processes.
Impact
• Enabled previously scrapped components to be approved
• Supported release of multiple engines into service
• Protected approximately £66M in engine value
• Resolved a problem that had remained unsolved for many years
Case Study 2 – Turbine Disc Paint Recovery
Organisation: Rolls-Royce
High-value turbine discs were failing paint adhesion requirements during a critical production period. This created risk of scrapping expensive components and missing delivery targets.
After reviewing repair documentation, I identified an existing approved repair process that could be adapted to address the paint failure.
Impact
• Prevented scrapping of high-value turbine discs
• Allowed discs to be recovered and released for use
• Protected production targets during a high-pressure delivery period
Case Study 3 – Blade Life Calculation Automation
Organisation: Rolls-Royce
Rotor blade life calculations were performed manually by inspectors using markings and reference tables. This process was time-consuming and susceptible to human error.
I created an automated Excel-based lookup tool that calculated blade life instantly based on the blade markings and required service hours.
Impact
• Reduced inspection time from approximately 16 hours to 3 hours
• Reduced risk of calculation errors
• Standardised a previously manual process
Case Study 4 – Wing Protection Accountability System
Organisation: Airbus
Temporary protective materials were installed and removed during wing assembly. A previous incident had involved protective material being left inside an aircraft, and the organisation had struggled for several years to guarantee full accountability of these items.
I designed a physical and visual tracking system that mapped protection components to the geometry of the wing structure.
Impact
• Guaranteed accountability of all temporary protection items
• Eliminated risk of foreign protection material remaining in aircraft
• Replaced complex spreadsheet tracking with a simple visual system
Case Study 5 – Sealant Application Consistency Tool
Organisation: Airbus
Sealant application around fasteners relied heavily on operator technique, leading to inconsistent results and potential rework.
I designed and prototyped a mechanical sealant metering and application tool that ensures consistent sealant volume and placement.
Impact
• Standardised sealant application geometry
• Reduced operator variation
• Potential to save hundreds of labour hours across aircraft builds
• Reduced inspection failures and rework
Case Study 6 – Navigation Light Protection Redesign
Organisation: Airbus
A navigation light protection system had been over-engineered and produced via brittle PLA 3D printing. The solution was fragile and required adhesive tape to secure it to the wing.
I redesigned the system using LDPE foam and compliant mounting anchors inserted into existing wing holes.
Impact
• Eliminated fragile 3D-printed parts
• Removed the need for tape on aircraft surfaces
• Reduced complexity and cost
• Created a more durable and production-friendly solution
Case Study 7 – Simplification of Aircraft Assembly Instructions (SOIs)
Organisation: Airbus
Complex assembly instructions were difficult for shop-floor teams to interpret, particularly as workforce experience levels changed.
My role involved reviewing and rewriting these instructions by understanding the engineering function of each system and translating it into clear, visual step-by-step guidance using CAD models.
Impact
• Improved clarity of build instructions for assembly teams
• Reduced reliance on tribal knowledge
• Improved consistency in aircraft assembly processes
• Simplified a backlog of approximately 200 instructions