Modeling a new Maintenance shop floor in Aircraft Industry

The Maintenance Division of an Airline Group repairs hundreds of engines from civil (Rolls Royce, Pratt, GE, CFMI) and military programs. The management team wish to make an important commitment in the design of a modern Maintenance shop for the airline companies market. The client belonged to a Group which had stayed in public ownership for a long time. The site is strongly syndicated, with a very sensitive social climate, and with a recent past without investment and almost no innovation.

The project objectives were:

  • Reach 200 revisions a year (current level = 100)
  • Make competitive the Unit, in particular on cycles and costs
  • Develop the technical skills to do complex revisions
  • Delivering increased value to the business

Our Approach

  • An initial analysis was made to understand the existing organization, to measure the real performances, and to detect key issues and weak points.
  • A benchmark was establlished to indicate the level of improvement required.
  • Working groups were formed to work with the Management team to research finnovative solutions and develop a target model.
  • In parallel the project team lead actions in the business to communicate, and obtain agreement and commitment on the plan.
  • An assessment and diagnosis of the current situation was made based on the following anasyses:
    • Value Steam Maps for existing products
    • Measures and observations on the organization using AV/NAV
    • Industrial and economic performance
    • Comments and feedback through 40 interviews
  • A set of targets were set and validated based on a market analysis, enabling the development of:
    • Specific objectives by activity
    • An action plan
  • A ‘breakthrough’ Target Model was developed including:
    • Redefinition of the Make or Buy strategy
    • Facility re-design based on FLOW of work
    • New Production Planning process, based on Pull System
    • Workflow control based on Visual Management and autonomous cellular units

The Action Plan by activity enabled staff to understand the actions in practice and measure and evaluate results as the project progressed.

Client benefits

  • The Target Model was tested and met all the objectives
  • The proposed plan was accepted by the General Management and the Shareholders