Client situation
The Client is a leading independent Maintenance, Repair & Overhaul (MRO) solution provider, specialized in APU, engine parts and landing Gear MRO, for civil and military aircraft. After the merger of its 3 main divisions, the Group identified the need to develop a common Operational Excellence program mainly targeting:
- Cost and cash flow optimization
- Productivity and capacity increase
- On-time-in-full (OTIF) improvement
- Review of the internal products flow
- Global cultural change.
Approach
EFESO supported the Client by:
- Designing and deploying an Operational Excellence program that we implemented in phases:
- Cost deployment & value stream mapping
- 15 projects implemented applying autonomous maintenance, SMED, breakdown reduction and business process improvement
- Review of performance management meetings in the landing gears plant
- Implementing a Lean and 6 sigma training program
- Coaching shop floor managers to achieve performance-oriented culture and digital implementation
Results
Business process results:
- -80% Lead Time for invoice process in one Division
- -30% number of pending practices for specific maintenance tool development
Maintenance and Repair processes results:
- 60% availability for surface treatment equipment
- - 75% breakdowns for surface treatment equipment through autonomous maintenance
- - 30% Lead Time for landing gear maintenance
Achievements for cultural change facilitation:
- Over 100 people (blue and white collars) trained to Lean methods and Problem Solving
- Standardization of two main operational practices through merged Divisions
