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Launching an Operational Excellence program for a MRO solution provider

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
 

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