Excellence in Engineering Project Management - A Case Study

Introduction

This case study highlights how Alphacron’s consultant successfully led the transition in the design and manufacture of a critical gearbox seal for a gas turbine engine. By applying a structured, multi‑phase programme, the consultant delivered a more robust and cost‑effective solution, demonstrating the impact of disciplined governance in engineering innovation.

Background

The gearbox seal, an oil/air seal preventing leakage through controlled air pressure, was originally produced via investment casting. While this process accommodated a complex oil drain feature, it also introduced challenges:

1. Porosity issues compromising reliability

2. High production costs

3. Process limitations restricting scalability

   
   

A review of service data revealed the oil drain feature was unnecessary. This insight opened the door to a more efficient approach: machining the seal from forging.

Project Governance and Delivery

A gated project management framework was applied, ensuring each stage advanced only when defined criteria were met. The programme unfolded in six phases:

Idea Generation & Business Case: Casting limitations were identified, a compelling business case for forging was built, and benefits in cost, durability, and manufacturability were quantified.

Supplier Selection: Procurement was overseen, technical and financial reviews of three candidates conducted, and the most capable forging and machining partners appointed.

Component Redesign: A cross‑functional redesign was coordinated, securing approvals from specialists in design, materials, bearings, air systems, stress, oil systems, weights, and thermals to ensure sealing performance and durability.

Process Development: Working with suppliers, machining processes were established, operational procedures introduced, and PPAP applied to assure quality.

Validation: Modal testing confirmed vibration and stress resilience, benchmarking results against the original design.

Production Integration: Coordination with production managers and material planners ensured seamless incorporation into the assembly line without disrupting ongoing builds of high-volume engines.

Role of the Project Management Consultant

Our project management consultant was central to the programme’s success:

• Developed and maintained the business case

• Directed a core team of 10+ members across three countries and time zones

• Engaged 27 stakeholders, ensuring alignment and transparency

• Provided leadership across technical, procurement, and client communication functions

This holistic oversight ensured risks were mitigated, opportunities captured, and delivery remained on schedule.

Outcome

The transition from casting to machining from forging delivered:

• Improved reliability through elimination of porosity issues

• Reduced manufacturing costs with a more efficient process

• Enhanced durability validated through rigorous testing

• Uninterrupted production during implementation

Conclusion

By combining technical insight with disciplined governance, the consultant transformed a manufacturing challenge into a strategic opportunity. Their leadership enabled the client to achieve a superior, cost‑effective solution, which reinforced the value of expert project management in the manufacturing sector.