Lycoming Engines Featured on "How It's Made"

how its made

A Logical Choice

Have you ever wondered how the best aircraft engines in the world are assembled? Tune to The Discovery Channel on Thursday, April 30, at 7:30 p.m. (Eastern), and from your own home you'll be able to follow the Lycoming engine assembly process from start to finish on "How It's Made."

In 2008, Production Maj, the Canadian company that produces the popular Discovery Network show, "How It's Made," visited Lycoming Engines in Williamsport, PA. The Lycoming segment joins the show's long list of featured manufacturing processes that cover literally everything from A to Z, from accordions to zippers.

"Recording the assembly of an aircraft engine was a logical choice," said Director Francsois Senecal-Tremblay, "and Lycoming stands out as the leader in your domain."

"How it's Made" is a unique show that has no host, no stars, and no story line. It's all about the product and the hands that build it. The show airs in dozens of countries and is broadcast in dozens of languages. Senecal-Tremblay explained that Production Maj contacted Lycoming because of his personal interest in aviation, having devoted segments of past shows to aircraft and aircraft parts. Before filming at Lycoming, the Montreal-based crew had been at Airship Management Services Inc., in Elizabeth City, NC, where, coincidentally, they witnessed the delivery of new Lycoming engines destined for installation on a blimp.

Lycoming has been continuously building aircraft engines in Williamsport since 1929 and has supplied well over 325,000 engines for airplanes, helicopters, aerobatic planes, and airships.

"All About Our People"

Ian Walsh, Lycoming's senior vice president and general manager, welcomed the opportunity to participate in this interesting and educational show.

"Lycoming Engines was proud to host Production Maj, the company that films and produces the internationally recognized show," Walsh said. "After two days of filming, Director Senecal- Tremblay said that the crew has filmed over 140 manufacturing segments in the last several years and singled out Lycoming's workforce as one of those with the highest sense of pride in their work that he has seen."

Walsh added, " 'How it's Made' may be all about the product, but Lycoming Engines is all about our people!"

how its made

When filming started, it was immediately obvious that Production Maj is a team of true professionals, mentally framing shots and asking all the right questions. The filming followed the assembly process, from components being fully inspected and verified to the assembled engine being painted and accessorized. The crew filmed the test cells where every engine is thoroughly tested at flight speeds and is checked to be sure it meets Lycoming's rigid quality standards before it goes through a final checklist and is prepared and crated for shipping.

The last piece filmed was of Ian Walsh piloting "Bulletproof," a 200 MPH Van's RV-8A aerobatic airplane, equipped with one of the first AEIO-390X Lycoming Thunderbolt engines. "Bulletproof" got its name from Lycoming's reputation for solid, safe, and dependable engines and has become something of a company mascot.

An Excellent Opportunity

Filming was only the first step, followed by months of editing, scripting, narration, and re-editing.

"This has been an excellent opportunity for Lycoming to show the world its Premier people, processes, products, and operations," said Tom Conway, Lycoming's Director of Production Planning/Inventory Control and Manufacturing Support Systems, and leader of the factory team that organized the preparations for the "How It's Made" filming. "It is a tribute to the legacy of Lycoming, and to our employees, past and present, who have demonstrated their pride in workmanship and commitment to being the best at what we do. Thanks to all who participated in making this a memorable event."

The Lycoming "How It's Made" episode debuted on the Science Channel on Jan. 23, 2009 and has aired several times on that network.

Media Contact

Communications
652 Oliver St.
Williamsport, PA 17701
(570) 327-7001

Communications@lycoming.com