Realization



Mro & Turnarounds

DELTA AIR LINES, INC., PF2010

LUFTHANSA TECHNIK

US NAVY, FLEET READINESS CENTER SE, P3

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Case Studies

From Multitasking to Synchronized Engine Maintenance
Leading airline reduces engine repair time by 30% and gains an extra quarter of production.

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Multitasking - Killer of Speed, Productivity and Customer Satisfaction
A leading airline reduces flight cancellations 62% by conquering multitasking in maintenance.

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Before & After

 BeforeAfter

Transformer Repair and Overhaul
  • 42 projects completed in 2007.
  • On-time delivery was 68%.
  • 54 projects completed in 2008.
  • On-time delivery improved to 83%.

Helicopter Maintenance, Repair and Overhaul
(For Flight Schools)
  • 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 savings).

Aircraft Engine Repair and Overhaul
  • 476 engines produced per year.
  • 4-8 weeks piece-part cycle time.
  • 60 days landing gear turnaround time.
  • 586 engines produced per year (23% increase).
  • 30% reduction in engine turnaround time.
  • 15 days piece-part cycle time (70% reduction).
  • 25% increase in throughput.
    30 days landing gear turnaround time (50% reduction).
  • $60M monetized in assets from reduced turnaround time.

 

Ongoing improvement:

  • 10 days piece-part turnaround time (30% further reduction).

Helicopter Manufacturing and Maintenance
  • Only 33% projects completed on time.
  • On-time delivery increased to 83%.

Aircraft Upgrade and Repair
  • 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.

Train Maintenance, Repair and Overhaul Engineering
  • 16 months delay in delivery of last order.
  • 1 order executed at a time.
  • 100% on-time delivery on all orders.
  • 3 orders executed in the same time frame.

Plant Maintenance and Upgrade
  • 300-500 days for boiler conversion.
  • Routine maintenance took too long.
  • 11 days planned for shutdown.
  • $2M revenue generated per day.
  • 120-160 days completion time (68% faster).
  • 10-33% reduction in 2007 cycle time.
  • 5-33% additional reduction in 2008 cycle time.
  • 8.8 days shutdown achieved.
  • $4M revenue gained.
    Set net operating hours industry record (6690 hours per year).

Defense Products Design and Manufacturing
  • Long project cycle times with frequent delays.
  • Difficult to synchronize Design and Manufacturing.
  • Project cycle times reduced by 20%.

War fighter Systems Testing
  • 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.

Aircraft Maintenance, Repair and Overhaul
  • 33 aircraft throughput in FY09.
  • 36 aircraft on station.
  • 44 aircraft throughput in FY10 (33% increase).
  • 24 aircraft on station, 12 aircraft returned to Air Force.

Aircraft Repair and Overhaul
  • 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 (additional revenue potential $35M).

Aircraft Upgrade and Repair
  • Produced 11 aircraft a year.
  • Cycle time of 225 days.
  • Produced 17 aircraft a year.
  • Cycle time of 195 days.

Aircraft Upgrade and Repair
  • 4 aircraft on base.
  • Cycle time of 183 days.
  • 2.6 aircraft on base on average.
  • Cycle time of 155 days.
  • 11% capacity released for additional workload.

Aircraft Maintenance, Repair and Overhaul
  • Average turnaround time was 327 days.
  • Average turnaround time reduced to 146 days.
  • 44% increase in throughput from Q4 2008 to Q4 2009.

Aircraft Engine Repair and Overhaul

Engine piece-part repair:

  • 137 days backshop cycle time.
  • 260 parts/month backshop throughput.


Engines and Modules:

  • 45 modules/month throughput.
  • 18 days cycle time.

Engine piece-part repair:

  • 42 days backshop cycle time (69% reduction).
  • 434 parts/month throughput (67% increase).

 

Engines and Modules:

  • 50 modules/month throughput (10% increase).
  • 8 days cycle time (55% reduction).

Aircraft Upgrade and Repair
  • 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% reduction in overtime.

Aircraft Repair and Overhaul
  • Turnaround time 240 days.
  • 13 aircraft in repair cycle.
  • Turnaround time 160 days.
  • 7 aircraft in repair cycle.
  • 75% fewer defects.

Helicopter Maintenance, Repair and Overhaul
  • Throughput of 5.4 aircraft per month.
  • Throughput for Black Hawk was much lower than required.
  • Turnaround times were unacceptable.
  • Work scope per aircraft was increasing.
  • Throughput increased to 6.3 aircraft per month.
  • Black Hawk throughput increased by 40% in just 6 months.
  • 50% reduction in Apache turnaround time.
  • 15% reduction in CH47 turnaround time.
  • 15% reduction in Pave Hawk turnaround time despite increased scope.

Army Vehicles Maintenance and Repair
  • 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
  • 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
  • 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
  • Produced 6 aircraft in 2008.
  • Produced 9 aircraft in the first 9 months of 2009.

Process Plant Turnaround (Nickel Smelting)
  • 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.