Singapore A*STAR: 20%+ Productivity Gains in Aerospace Manufacturing

Singapore's aerospace manufacturing sector faced increasing global competition and pressure to maintain its position in the high-value aerospace supply chain. Rolls-Royce's fan blade manufacturing and SAESL's MRO operations needed to meet growing global aviation demand while improving productivity, precision, and cost efficiency. Traditional manufacturing processes were reaching their limits in terms of output, quality consistency, and operational efficiency. Local aerospace SMEs in Singapore's ecosystem lacked the capabilities and technology know-how to qualify as approved vendors for global aerospace prime contractors, limiting their participation in the lucrative global supply chain. Without technology transformation and skills upgrading, Singapore risked losing aerospace manufacturing activities to lower-cost locations.

ASTAR's Advanced Remanufacturing and Technology Centre (ARTC) designed and executed a multi-phase advanced manufacturing transformation programme for Rolls-Royce and SAESL. The partnership deployed 18 distinct advanced technologies across the facilities, including autonomous systems, robotics, intelligent inspection systems, industrial artificial intelligence, IoT sensors, and advanced process optimization tools. ASTAR provided technical expertise, research facilities, and hands-on engineering support to customize and integrate these technologies into existing production lines. Phase one focused on validating technologies and demonstrating initial operational improvements, while phase two deepened and scaled the gains across additional production areas. The programme also engaged over 200 Singapore SMEs through the Singapore Aerospace Manufacturing Joint Lab (SMJL), providing technology exposure, skills training, and business opportunities to help local firms qualify as approved vendors for the aerospace supply chain.

The advanced manufacturing deployment delivered over 20% productivity gains across Rolls-Royce's fan blade facility and SAESL's MRO operations. The technologies enabled faster production cycles, improved quality consistency, reduced manual intervention, and enhanced predictive maintenance capabilities. Beyond the direct productivity improvements, the SMJL engagement with over 200 Singapore SMEs generated S$4.5 million (approximately US$3.3 million) in immediate business opportunities and enabled eight local enterprises to successfully qualify as approved aerospace vendors, entering the global supply chain. A*STAR has deployed more than 100 advanced manufacturing solutions across various sectors to date, demonstrating the scalability and replicability of the approach. The success contributed to Coca-Cola Singapore's recognition as a World Economic Forum Global Lighthouse facility in 2024, showcasing Singapore's growing reputation for manufacturing innovation.

The ASTAR partnership model demonstrates the effectiveness of government research institutes serving as technology bridges between global manufacturers and local SME ecosystems. By focusing on co-development and hands-on integration rather than just funding, ASTAR built deep technical capabilities that deliver measurable productivity gains. The two-phase approach—validating technologies first, then scaling—reduces risk for industry partners while building confidence in advanced manufacturing investments. The 20%+ productivity improvements prove that even highly sophisticated aerospace manufacturing can achieve step-change performance through systematic technology deployment. Most importantly, the programme's success in helping eight local SMEs qualify as aerospace vendors demonstrates how government-led innovation partnerships can create lasting ecosystem benefits that extend far beyond the initial prime contractor participants.