Rolls-Royce Canada

The engine workscope definition is created considering the reason for removal, configuration, service life consumed, health monitoring and build life objective aligned to the Engine Management Plan (EMP) and Technical Publications.

Our Engineering team leverage our digital estate to understand high level engine workscope definition prior to engine removal. This provides the insight we need, in time, to deal with less routine topics and optimally slot an engine for induction. As we get closer to the pre-induction date (typically one week before induction) detailed engine workscope definition is completed and the necessary commercial approvals are secured.

Aligned to the workscope, our highly skilled fitters will disassemble the engine to modules, subassemblies and piece parts to facilitate the EMP defined level of inspection and execute the workscope requirements. The modules and engine will be re-assembled, incorporating the required replacement parts (configuration) strictly adhering to the Engine Manual (EM) fixed processes, including state-of-the-art straight build and balancing controls.

Aligned to the workscope, our highly skilled inspectors will inspect the engine, modules, subassemblies and piece parts to facilitate the EMP defined level of inspection, executing the workscope requirements. Inspectors ensure that through visual, dimensional or NDT inspection fixed process specifications within the EM are adhered to, providing disposition on serviceability and repair, while incorporating the required replacement parts (configuration and life control).

We complete the vast majority of our CR activities in house, driving the most sustainable solutions wherever possible. We have implemented automated chemical processing and cleaning systems, dramatically reducing our use of chemicals. At the same time, we are expanding our Ultra High Pressure Waterjet capabilities and capacities to drive greener solutions.

Repairing as opposed to replacing parts of the engine, when done sustainably, is the best way to reduce our carbon footprint. We have leading edge robotic, CNC and optically controlled machine tool and measurement system capabilities, underpinned by our extensive Special Processes that enable us to provide the extensive array of CR capabilities in our shop.

A ‘Special Process’ is a process that cannot be fully inspected or tested after completion and for which we must rely on “Fixed Process Control” (FPC). We have six Special Processes in Montreal, all fully NADCAP certified ensuring that our FPC remains at the precipice of compliance and efficiency underpinning our CR processes.

• Chemical processes such as painting and plating. We have recently installed a state-of-the-art automated Chemical Processing Line
• Welding
• NDT (Non-Destructive Testing) such as crack testing, fluorescent penetrant inspection, eddy current testing, magnetic particle inspection and ultrasonic testing
• Heat treatment using vacuum and air circulation
• Surface enhancement using computer controlled shot peen
• Coatings and thermal spray

We have two certified Aero Test Facilities at our Montreal site. The larger of the two was originally built to support the Aero RB211 engine but now supports all MRO activity products and development testing. The second facility is also fully certified to support the products in our portfolio, enabling full onsite redundancy from a business continuity perspective.

We established the development test capability in Montreal in 2016 specifically to support the latest generation of product introductions for Business Aviation – the Pearl engine series.

Over recent years we have supported many specialised tests, several of which are unique to our capabilities. This includes cold start – a process of cold soaking the engine down to minus 40 degrees Celsius to demonstrate start capability. We also support water ingestion testing, cyclic endurance and a host of other experiments.

We are at the forefront of digital innovation, leveraging cutting-edge technologies to drive efficiency, precision and productivity. Through advanced automation, including robotics and IIoT (Industrial Internet of Things) powered MRO critical assets, we are fostering a transformative culture of predictive maintenance, minimised downtime and optimised workflows.

Our cloud and edge computing capabilities enable secure, high-speed big data processing for smarter, faster decision-making. Additionally, the integration of 3D definition models into our processes enhances production activities by improving visualisation, accuracy and efficiency. By adopting these next-generation solutions, we are setting new standards in smart manufacturing, delivering exceptional quality and performance.