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Title
Rolls-Royce uses AI turbine blade inspection and engine health monitoring to prevent 400 maintenance events a year
…than 10,000 engine parameters with exceptional data quality. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned maintenance events a year, saving millions in repair costs and minimizing disruptions for customers. Accelerating innovation This is just the beginning. These advanced digital solu…
Description
Rolls-Royce uses Microsoft Cloud for Manufacturing, Azure Databricks, and generative AI across engine design, turbine production, and engine health monitoring. Its 'Signature Analyzer' AI/machine learning system inspects turbine blade cooling holes (previously about 2 million inspected manually per month), using machine vibration analysis and generative AI to optimize defect detection, boosting machine utilization 30% and accelerating fault resolution from days to near real time. AI-powered engine health monitoring tracks more than 10,000 engine parameters and detects and prevents around 400 unplanned maintenance events a year, saving millions in repair costs.
…ction was incredibly time-consuming and often created a production bottleneck. “Historically, we inspected about 2 million cooling holes per month manually,” says Tim Pickup, Digital Manufacturing Lead at Rolls-Royce. “With Microsoft AI, we’re able to optimize manual inspection, dramatically redu…
…ng inspectors to focus on specific areas rather than having to check each hole. This has boosted machine utilization by 30%, significantly minimized erroneous scrap from the manual inspection process, and accelerated fault resolution from days to near real time. AI-powered engine health monitoring: Maximizing time on wing Advancements in di…
…ground. Fueled by Microsoft Cloud for Manufacturing and cloud-based analytics, this system tracks more than 10,000 engine parameters with exceptional data quality. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned maint…
…than 10,000 engine parameters with exceptional data quality. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned maintenance events a year, saving millions in repair costs and minimizing disruptions for customers. Accelerating innovation This is just the beginning. These advanced digital solu…
Company
Rolls-Royce
…illions of euros in cost avoidance Fault resolution from days to near real time For more than a century, Rolls-Royce has been a force for progress, powering, protecting, and connecting people everywhere. From propulsion to power solutions, on land, at sea, and in the air, the compan…
Country
United Kingdom
…D SUPPORT Microsoft Cloud for Manufacturing ORGANIZATION SIZE 10,000+ employees COUNTRY/REGION United Kingdom BUSINESS NEED Artificial Intelligence INDUSTRY Discrete Manufacturing Share the…
Industry
Aerospace & Defense
…ital technology are blurring the line between product and aftermarket services. The Rolls-Royce Pearl aircraft engine family features the state-of-the-art Engine Vibration Health Monitoring Unit (EVHMU), enhancing on-wing intelligence for best-in-class availability and predictive m…
Problem
Rolls-Royce wanted to improve productivity and reduce costs across its design, build, and operate functions. Manual inspection of turbine blade cooling holes was incredibly time-consuming and often created a production bottleneck.
…des, to protect them from the extreme heat generated by the combustion process. Manual inspection was incredibly time-consuming and often created a production bottleneck. “Historically, we inspected about 2 million cooling holes per month manually,”…
Solution
Rolls-Royce uses Microsoft Cloud for Manufacturing and technology stacks such as Microsoft Azure Databricks, Unity Catalog, and high-powered GPUs to accelerate engine design. Its "Signature Analyzer" system uses machine vibration analysis and generative AI to optimize turbine blade defect detection, and AI-powered engine health monitoring (via the Engine Vibration Health Monitoring Unit) tracks more than 10,000 engine parameters for predictive maintenance.
…engine design Engine design was traditionally a manual process that took years. Now, with technology stacks such as Microsoft Azure Databricks , Unity Catalog, and high-powered GPUs, engineers can explore a broader range of design parameters in hours. AI-powered automation speeds up component selection and assembly, reducing manu…
…anual inspection, dramatically reducing the processing time of each component.” Machine vibration analysis and generative AI have optimized defect detection, enabling inspectors to focus on specific areas rather than having to check each hole. This has boosted machine utilization by 30%, significantly minimized erroneous…
…olls-Royce can remotely reconfigure engine monitoring features from the ground. Fueled by Microsoft Cloud for Manufacturing and cloud-based analytics, this system tracks more than 10,000 engine parameters with exceptional data quality. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned mainte…
Business value
This has boosted machine utilization by 30%, significantly minimized erroneous scrap from the manual inspection process, and accelerated fault resolution from days to near real time. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned maintenance events a year, saving millions in repair costs and minimizing disruptions for customers.
…ng inspectors to focus on specific areas rather than having to check each hole. This has boosted machine utilization by 30%, significantly minimized erroneous scrap from the manual inspection process, and accelerated fault resolution from days to near real time. AI-powered engine health monitoring: Maximizing time on wing Advancements in di…
…than 10,000 engine parameters with exceptional data quality. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned maintenance events a year, saving millions in repair costs and minimizing disruptions for customers. Accelerating innovation This is just the beginning. These advanced digital solu…
AI capabilities
Generative AI, Computer Vision, Predictive Analytics
…anual inspection, dramatically reducing the processing time of each component.” Machine vibration analysis and generative AI have optimized defect detection, enabling inspectors to focus on specific areas rather than having to check each hole. This has boosted machine utilization by 30%, significantly minimized erroneous…
Technology
Microsoft Azure Databricks, Unity Catalog, Microsoft Cloud for Manufacturing
…engine design Engine design was traditionally a manual process that took years. Now, with technology stacks such as Microsoft Azure Databricks , Unity Catalog, and high-powered GPUs, engineers can explore a broader range of design parameters in hours. AI-powered automation speeds up component selection and assembly, reducing manu…
…olls-Royce can remotely reconfigure engine monitoring features from the ground. Fueled by Microsoft Cloud for Manufacturing and cloud-based analytics, this system tracks more than 10,000 engine parameters with exceptional data quality. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned mainte…
Deployment model
cloud
…ef Digital Info Officer, Rolls-Royce Discover more details CUSTOMER Rolls Royce PRODUCTS Azure Azure Databricks SERVICES AND SUPPORT Microsoft Cloud for Manufacturing ORGANIZATION SIZE 10,000…
Deployment options
cloud
…ef Digital Info Officer, Rolls-Royce Discover more details CUSTOMER Rolls Royce PRODUCTS Azure Azure Databricks SERVICES AND SUPPORT Microsoft Cloud for Manufacturing ORGANIZATION SIZE 10,000…
Headline outcome
…than 10,000 engine parameters with exceptional data quality. Across all fleets, Rolls-Royce detects and prevents around 400 unplanned maintenance events a year, saving millions in repair costs and minimizing disruptions for customers. Accelerating innovation This is just the beginning. These advanced digital solu…
Use case type
Visual inspection
…siveness to industry demands. Keeping cool: AI-powered turbine blade inspection Rolls-Royce is also using AI and machine learning to revolutionize its turbine blade manufacturing with “Signature Analyzer,” predicting defects quickly and efficiently. Workers create a sophisticated system of cooling channels and holes across the…
