Industry Solutions

Maintenance, Repair, and Overhaul (MRO)

The need for improving operational performance in the MRO industry is in high demand. Most organizations have implemented Lean and Six Sigma programs and they have made incremental improvements. However, this is not enough. There is a need for a quantum jump in turnaround time, throughput, and cost performance. Realization has helped MRO organizations achieve a 25-50% reduction in turnaround time and more than 25% improvement in throughput within months!

1 Minute MRO Video Case Studies

Delta Air Lines
Commercial

MRO Resources

Aircraft Maintenance
Military Aircraft MRO
Engine MRO
MRO Articles
MRO Webcast
MRO Results

Aircraft Maintenance

Every aircraft maintenance operation is looking to decrease turnaround time, improve throughput and reduce cost all at the same time. In most cases, improvement initiatives like Lean & Six Sigma have resulted in incremental improvements in the range of 5 to 10% over a few years. This is because these initiatives fail to address a fundamental issue in MRO execution.

It is a well know fact that in MRO operations, multiple things such as parts, mechanics, tools, equipment, paperwork, etc have to come together at each of the repair process to ensure smooth execution. If anyone of these is missing, execution slows down (cycle time goes up) and productivity suffers (throughput comes down). In a nutshell, every MRO manager knows "synchronization" is the key to superior execution in MRO. At the same time, MRO managers will readily admit that it is a challenge to synchronize multiple things at each step of the repair process. In fact, managers spend most of their day "chasing" issues or missing things in order to get each step completed.

The reason why synchronization is so difficult in MRO is because of uncertainties. In a perfect world without uncertainties, one could schedule all the activities (within and across aircraft) and execute to the schedule. Unfortunately, uncertainties render any fixed plan or schedule obsolete as soon as execution begins. Unlike traditional project management, which focuses on more detailed planning and tracking adherence to that plan, Realization places its emphasis on synchronizing activities during execution to ensure that everyone is working on the same priorities despite uncertainties.

Solving the synchronization problem in MRO delivers immediate benefits like 25 to 33% reduction in turn around time; 25+% increase in throughput and a jump in on-time performance. To date, Realization has implemented its solutions at several aviation MRO operations, both military and commercial.

Call us at 408.271.5100 to learn more on how we can help your organization increase Throughput and reduce Turnaround Time within months.

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Military Aircraft MRO

Fleet readiness is a crucial need for the military. At any given time, a minimum number of aircraft have to be ready for their mission. On one hand, the workload on these aircraft is increasing and on the other hand, since these aircraft (and their spares) are very expensive, there are budgetary pressures to limit the fleet size. Combination of these two opposing pressures make fleet readiness very challenging.

MRO for military aircraft is performed at various levels. The operational level repairs and inspections are done at the operating locations. The intermediate level of maintenance and inspections are done at certain bases or at commercial contractor facilities. The large overhauls are performed both at the organic maintenance depots as well as by commercial MRO operators.

Both the maintenance depots and the commercial MRO operators are feeling the pressure of improving fleet readiness. The customers (the operating commands) are first and foremost asking them to deliver their aircraft on time without schedule extensions. In addition, they are also asking the depots and MRO providers to reduce the turnaround time and reduce the number of aircraft in overhaul status at any given time. Finally, the customers are putting pressure to reduce the cost of maintenance.

Military aircraft MRO operations have similar execution challenges like any other MRO. They have a great deal of uncertainties associated with maintenance work. Some of the uncertainties they deal with are:

  • Significant (30+%) amount of unplanned work discovered after inspections
  • Special repairs that need extensive engineering support
  • Parts shortages
  • New issues discovered during assembly and testing
  • Rework associated with repairing ageing aircraft
  • Vendor, backshop delays
  • Paperwork delays, customer approval delays, funding delays, etc.

In addition, military aircraft MRO operators face a set of unique challenges. First of all, military aircraft are typically used in more adverse conditions than commercial aircraft thereby impacting the extent of stress and corrosion found on these aircraft. Secondly, the amount of structural repair work done on these aircraft is more extensive than what is typically observed on the commercial aircraft. Finally, since some of these aircraft are over 40 to 50 years old and as a result MRO operators also struggle with engineering and material obsolescence issues.

The following Military Aircraft articles show that how did Realization play an important role in helping leading MRO organizations overcome their challenges that are mentioned above. To view these articles, please click on the links below:

Call us at 408.271.5100 to learn more on how Realization has helped Military Aircraft organizations receive significant improvements and an increase in Fleet availability within months. To see the results of Warner Robins, watch this video.

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Engine MRO

Aircraft engines are expensive assets for the airlines. As a result, airlines are trying to minimize the inventory of ready engines being held. This puts pressure on engine MRO operators to reduce turnaround times for overhauling the engines.

Engine MRO operations are complex. After induction, the engine is disassembled and inspected. Hundreds of parts coming out from the engine are then repaired through a series of shops, both internal and external. All these parts have to come back to the assembly point at the right time. Synchronizing the hundreds of parts to come back to assembly point is a huge challenge. Most often some of these parts are missing at the assembly point. This causes delays, expediting, fire-fighting and loss of throughput.

To see how Delta Air Lines engine MRO synchronized their performance, please watch this video.

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MRO Articles

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MRO Webcasts

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MRO Results


B E F O R E

A F T E R

Helicopter Maintenance, Repair and Overhaul (For Flight Schools)
Army Fleet Support

Maintenance workload increased by 37% and turnaround times were long, leading to helicopter shortages.

32% reduction in CH-47 turnaround time. 52% reduction in UH-60 turnaround time. 8 aircraft returned to customer ($90M in cost avoidance). 18,000 sq ft of hangar space freed up ($2M in cost avoidance).

Helicopter Maintenance, Repair and Overhaul
Corpus Christi Army Depot

Throughput of 5.4 aircraft per month. Work scope per aircraft was increasing. Turnaround times were unacceptable.

Throughput increased to 6.3 aircraft per month. 50% reduction in Apache turnaround time. 15% reduction in CH47 turnaround time. 15% reduction in Pavehawk turnaround time.

Engine Repair & Overhaul
Delta Air Lines, Inc.

Produced 40 engines per month.
4 weeks piece-part cycle time.

Increased production to 50+ engines per month, with 16%-26% reduction in engine turnaround time. 2.5 weeks piece-part cycle time, with 25% increase in throughput.
Helicopter Manufacturing and Maintenance
Erickson Air-Crane

Only 33% projects completed on time.

Projects completed on-time increased to 83%.
Aircraft Upgrade and Repair
French Air Force, SIAé Clermont Ferrand Transall Production Line		 5 aircraft on station. Cycle time of 165 days. 3 aircraft on station, 2 aircraft returned to Air Force, a replacement value of €300 M. 15% cycle time reduction, 15% increase in output with 13% fewer resources; 22% reduction in support shops’ cycle time.

Steel Plant Maintenance
TATA Steel

Boiler Conversion projects took 300-500 days. Routine maintenance and upgrade took too long.

Boiler Conversion projects took 120-160 days. In 2007, 1st year of Critical Chain, reduced maintenance and upgrade cycle times by 10-33% (savings of $13.4 million). In 2008, achieved a further 5-33% reduction in cycle time.
Aircraft Repair and Overhaul
US Air Force, Ogden Air Logistics Center
C130 Production Line		 21-24 aircrafts on station. Reduced to 18 aircraft on station. 25 out of 26 aircraft delivered on time or early (191 days of aggregate early delivery in 6 months).
Aircraft Repair and Overhaul
US Air Force, Oklahoma City Air Logistics Center
B-1Production Line		 Turnaround time 162 days.
7 aircraft in repair cycle.		 Turnaround time reduced to 115 days. 4 aircraft in repair cycle (3 returned to customer). Production output increased from 185 hours/day to 273. 1 ½ dock spaces freed up.
Aircraft Repair and Overhaul
US Air Force, Oklahoma City Air Logistics Center
B52 Production Line		 Produced 11 aircraft a year.
Cycle time of 225 days.		 Produced 17 aircraft a year.
Cycle time of 195 days.
Aircraft Repair and Overhaul
US Air Force, Oklahoma City Air Logistics Center
E3 Production Line		 4 aircraft on base. Cycle time of 183 days. On average 2.6 aircraft on base. Cycle time of 155 days. 11% capacity released for additional workload.
Aircraft Maintenance, Repair and Overhaul
US Air Force, Tinker Air Force Base
KC135 Production Line		 Average turnaround time was 327 days. Average turnaround time reduced to 146 days. 44% increase in throughput from Q4 2008 to Q4 2009.
Aircraft Repair and Overhaul
US Air Force, Warner Robins Air Logistics Center
C5 Production Line		 Turnaround time 240 days.
13 aircraft in repair cycle.		 Turnaround time 160 days.
7 aircraft in repair cycle.
75% fewer defects.
Aircraft Repair and Overhaul
US Air Force, Warner Robins Air Logistics Center
C17 Production Line		 Throughput of 178 hours per aircraft per day. Turnaround time 46-180 days. Mechanic output was 3.6 hours per day. 25% increase in throughput. Turnaround time reduced to 37-121 days. Mechanic output increased to 4.75 hours per day. 40% overtime reduction.
Warfighter Systems Testing
US Airforce Operational Test & Evaluation Center		 Long cycle times. Low utilization of resources. Poor visibility of project slips. 30% reduction in cycle time measured over 900 projects. 30% improvement in resource utilization. 88% on-time delivery performance.

Army Vehicles Maintenance and Repair
US Marine Corps Logistics Base, Barstow, CA

Repair cycle time for MK48 was 168 days. Repair cycle time for LAV25 was 180 days. Repair cycle time for MK14 was 152 days. Repair cycle time for LAVAT was 182 days..

Repair cycle time for MK48 reduced to 82 days. Repair cycle time for LAV25 reduced to 124 days. Repair cycle time for MK14 reduced to 59 days. Repair cycle time for LAVAT reduced to 122 days.

Aircraft Repair and Overhaul
US Naval Aviation Depot, Cherry Point

Average turnaround time for H-46 was 225 days. Average turnaround time for H-53 was 310 days. Throughput was 23 aircraft per year.

Reduced H-46 turnaround time to 167 days, while work scope was increasing. Reduced H-53 turnaround time to 180 days. Delivered 23 aircraft in the first 6 months. Throughput increased to 46 aircraft per year.

Submarine Maintenance and Repair
US Naval Shipyard, Pearl Harbor

Job completion rate was 94%. On-time delivery was less than 60%. Cost per job was $5,043.

Job completion rate increased to 98%. Increased on-time delivery to 95+%. Reduced cost per job to $3,355, a 33% reduction. Overtime dropped by 49%, a $9M saving in the first year.

Aircraft Maintenance and Upgrades
US Navy, Fleet Readiness Center Southeast, P-3

Produced 6 aircraft in 2008.

Produced 9 aircraft in the first 9 months of 2009.

Process Plant Turnaround (Nickel Smelting)
Votorantim

Projects were late and over budget.

Project 1 delivered on time. Project 2 delivered 1 day earlier (with 10% extra scope). Actual cost was 96% of planned budget.
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