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Inside SAESL: A Look into Its S$242 Million Investment and Expansion

  • 05 Feb 2025

Stepping into Singapore Aero Engine Services Private Limited (SAESL), one is immediately struck by the scale and rigour of its operations. The facility hums with the synchronised activity of heavy machinery, automated systems, and skilled technicians working in unison. Trent engines from the world’s leading commercial aircraft—Airbus A330s, A350s, A380s, and Boeing 787 Dreamliners—are meticulously disassembled, inspected, repaired, reassembled, and tested with precision.  A digital thread connects the shop floor, enabling efficient decision-making and optimised operations by seamlessly integrating data across the entire workflow.

Now, SAESL, a joint venture between Rolls-Royce and SIA Engineering Company, is gearing up for another major upgrade. With a substantial S$242 million (US$180 million) investment, the company has kickstarted expansion projects to increase its maintenance, repair, and overhaul (MRO) capacity by 40%, aiming to handle approximately 400 engines annually by 2028. This ambitious development will cement SAESL’s status as the world’s largest MRO facility for Rolls-Royce’s latest-generation engines. 

The new 26,000 sqm facility in development at SAESL in Calshot Road will serving as the 'nerve center' of its operations. Image: SAESL

A New Nerve Centre, the Future of Engine Inspection

On 16 January 2025, Deputy Prime Minister and Minister for Trade and Industry, Gan Kim Yong, officiated the groundbreaking ceremony for SAESL’s expansion at Calshot Road. SAESL’s latest development will integrate a new, state-of-the-art 26,000 sqm facility with the company’s existing five buildings, expanding its total footprint to 86,000 sqm.

This new facility will be able house over 100 engines at any given time and serve as the ‘nerve centre’ of SAESL’s operations.

Supported by 2,000 skilled workers, each engine that passes through the SAESL facility is broken down and undergoes scrutiny, part by part, down to its nuts and bolts, to determine whether it requires repair or replacement. SAESL is capable of repairing over 80% of all components in the engine. This includes complex components such as fan blades, nozzle guide vanes, combustion liners, and compressor stator vanes.

There are more than 18,000 parts in a single engine, and with so many engines being processed at a time, careful tracking and coordination are essential. To manage this efficiently, the Calshot facility will incorporate an intricate logistics network with advanced automation, Automated Storage and Retrieval Systems (ASRS) and Autonomous Mobile Robots, to streamline the delivery of kits to production cells.

Advanced Repair Capabilities in Seletar

Alongside the Calshot development, SAESL is also expanding its operations into existing 25,000sqm facility at the Rolls-Royce campus in Seletar Aerospace Park. Work to redevelop the Seletar space began in November 2024, and the first phase of its operations which will involve engine disassembly, assembly, and testing, is set to commence by the end of January 2025.

By 2026, SAESL’s Seletar plant will expand its capabilities to include module and component repairs, followed by the advanced repair techniques for large engine components in 2027. With the Advanced Repair and Seal Segment Cell, SAESL will be the first among Rolls-Royce’s global network to industrialise at scale advanced repair capabilities such as additive manufacturing, adaptive machining, and non-contact measurement on hot-end components. Applications include direct laser deposition of seal segments, compressor blisk cropping and tip repair, and Low-Pressure Turbine (LPT) disc seal fin repair.

The engine test cell at SAESL, is capable of testing engines of up to 140 inches in diameter and 70,000 kg of thrust; providing SAESL with the capability to carry out full engine tests on all current Trent engines. Photo: AAIS

Driving Innovation, Fortifying the Ecosystem

SAESL’s expansion is not just about physical growth; technology investments are a significant part of its strategy. Together with Rolls-Royce and A*STAR, SAESL is entering Phase 2 of the Smart Manufacturing Joint Lab (SMJL) with an additional S$34 million investment. This builds on the S$68 million invested in Phase 1, which successfully delivered 18 projects.

One groundbreaking innovation that has been deployed at SAESL is its Automated Visual Inspection (AVI) system, which won the Technological Impact of the Year Award from the British Chamber of Commerce Singapore and the SBR National Business Awards in 2024. Developed in collaboration with A*STAR and Rolls-Royce under the Smart Manufacturing Joint Lab, this advanced system employs high-resolution cameras and AI-powered image processing algorithms to detect defects in engine components, including dents, scratches, and cracks.

“Previously, technicians would spend hours manually inspecting every component,” explains Portfolio Manager Naeem Mansor. “This automated system reduces cycle time by 50% and cuts down man-hours by 80%. It allows technicians to focus on higher-value tasks that can help improve engine lifecycle management.” The automation system also brings the advantage of minimising human errors and fatigue associated with manual inspections, thereby improving overall inspection quality and safety.

SAESL’s AVI uses a camera mounted on a robotic arm and Deep Learning AI to analyse, detect and classify defects in engine parts. Photo: AAIS

Additionally, over 200 local SMEs have found opportunities to collaborate with Rolls-Royce and SAESL to develop and supply new manufacturing and MRO capabilities and services. Among them are Zincode Technologies and Sysmatic Global, which have become key suppliers, providing automated aero-engine component inspection services. Moving forward, Phase 2 will focus on developing AI-driven predictive maintenance, enhancing re-manufacturing techniques, and streamlining engine assembly and disassembly processes.

Training Next-Gen MRO Experts

With technological transformation comes workforce evolution. SAESL is investing heavily in training initiatives to ensure its workforce remains agile and in pace with advancements in engine and shop floor technologies. For example, training initiatives associated with the Smart Inspection System have upskilled employees in robotic programming, AI data modelling, and automation equipment handling.

At SAESL’s training workshop, new technicians undergo a rigorous year-long programme that combines three months of intensive classroom training with nine months of hands-on on-the-job training (OJT) on the shop floor. Trainees start by practising with small engines containing over 280 parts, learning to inspect defects, follow maintenance manuals, and master repair documentation, instilling rigour, discipline, and an emphasis on safety practices.

Minister Gan Kim Yong visits SAESL’s training workshop, where new technicians hone and practice their skills. Photo: SAESL

The company has partnered with Workforce Singapore and the Association of Aerospace Industries (Singapore) (AAIS) to leverage the Career Conversion Programme for Aerospace, ensuring its workforce remains future-ready.

Beyond enhancing current expertise, SAESL also announced that the expansion will create 500 new high-value aerospace jobs by 2028, opening doors for Singaporean talent.

Industry and government representatives gathered to celebrate SAESL’s groundbreaking ceremony, marking the start of its exciting expansion. Photo: AAIS

Primed and Positioned for the Next Wave

With modest beginnings in 1999, starting with 200 employees in a single building, SAESL has grown into one of the world’s largest Rolls-Royce Trent engine MRO providers. Today, over 20% of the world’s Rolls-Royce Trent engines pass through its facility.

The S$242 million expansion marks a new chapter for SAESL. With cutting-edge facilities pioneering advanced repair technologies and a steadfast commitment to workforce development and sustainability, the company is setting new standards in MRO excellence. Our heartiest congratulations to SAESL, Rolls-Royce and SIA Engineering Company on these significant developments, which will further strengthen SAESL’s position in engine MRO while contributing to the broader growth of Singapore’s aerospace sector.

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