Optimizing Parts Delivery for Efficient Airplane C Check Operations in MRO

Proval Consulting > Material Management > Optimizing Parts Delivery for Efficient Airplane C Check Operations in MRO

Introduction:

In the dynamic and time-sensitive field of Maintenance, Repair, and Overhaul (MRO), ensuring timely delivery of parts to the shop floor is critical for smooth operations, especially during rigorous tasks such as Airplane C checks. This case study explores how a client faced challenges in timely parts delivery for over a year and how a strategic approach, guided by the 80/20 Pareto rule, led to significant improvements.

Challenges:

The client, a prominent player in the aviation industry, struggled with consistent delays in delivering parts to the shop floor for their Airplane C check operations. This persistent issue impacted operational efficiency, causing setbacks and affecting overall performance.

Identification of Key Metrics:

To address the challenges, a thorough analysis was conducted using the 80/20 Pareto rule, leading to the identification of four critical metrics:

  • Inventory Accuracy: Accurate and real-time inventory management was crucial to prevent discrepancies and ensure the availability of required parts.
  • Parts Delivered Within a Two-Hour Window: Time is of the essence in MRO operations, and the client aimed to streamline the process by delivering parts within a two-hour window from the time of request.
  • Parts Ordered the Previous Day: Proactive planning was identified as a key factor in overcoming delays, emphasizing the importance of ordering parts in advance to meet the demands of the shop floor.
  • Parts Returned to Stock: Efficient management of returned parts played a significant role in maintaining a streamlined inventory and reducing waste.

Implementation of Measurement and Monitoring:

With the identified metrics, the client initiated a systematic measurement and monitoring process to track and analyze the performance of each parameter. This involved implementing robust tracking systems, investing in technology, and establishing clear communication channels between inventory management and shop floor teams.

Results and Impact:

The implementation of the measurement and monitoring systems resulted in significant improvements across the identified metrics. The impact was observed in:

  • Inventory Accuracy: Achieved a notable increase in accuracy, minimizing errors in inventory tracking and improving the reliability of available stock.
  • Parts Delivered Within a Two-Hour Window: Marked improvement in the timeliness of parts delivery, ensuring that critical components reached the shop floor within the specified timeframe.
  • Parts Ordered the Previous Day: Proactive planning led to a reduction in last-minute rush orders, contributing to a more efficient workflow and minimizing delays.
  • Parts Returned to Stock: Implemented streamlined processes for handling returned parts, reducing instances of mismanagement and optimizing overall inventory control.

Conclusion:

By applying the 80/20 Pareto rule and focusing on key metrics, the client successfully transformed their parts delivery process for Airplane C checks. The strategic measurement and monitoring approach not only addressed the immediate challenges but also laid the foundation for sustained improvements in efficiency and operational excellence within the MRO domain. This case study highlights the importance of data-driven decision-making and continuous improvement in meeting the demands of complex and time-sensitive aviation operations.

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Project Details

  • Category: Material Management
  • Client: MRO (aviation industry)
  • Location: U.S.A
  • Duration: 2 months
  • Results: Inventory Accuracy Improved Parts Delivery