Modeling a new Maintenance shop floor in Aircraft Industry

A Maintenance Division of an Airline Group wishes to make a commitment on the design of a modern maintenance shop for airline companies market.


The MAINTENANCE Division of an Airline Group repairs hundreds of engines issued from civil (RollsRoyce, Pratt, GE, CFMI) and military programs. The General management wishes to make a commitment in an important work of thinking on the design of a modern Maintenance shop for the airline companies market. Belonging to a Group which stayed public for a long time, the site is strongly syndicated, with a very sensitive social climate, a recent past without investment and almost no innovation.




  • Reach 200 revisions a year (current level = 100)
  • Make competitive the Unit, in particular on cycles and costs
  • Develop the technical skills to do complex revisions



  • A first analysis was driven to understand the existing organization, to measure the real performances, and to detect key and weak points.
  • A benchmark was realized to estimate the level of the challenge.
  • Working groups were constituted to associate the Management in the research for innovative solutions and with the construction of the target model.
  • In parallel of this work of conception, the project Team leads actions on the field to obtain a progressive appropriation by the concerned actors:
    • Targeted communication actions
    • Workshops in the shop and in the offices



  • Understanding of the Existing through 4 complementary axes resulting in a diagnosis:
    • Analysis of representative products thanks to VSM
    • Analysis of the organization and observations with measures of AV/NAV
    • Analysis of the industrial and economic performances
    • Analysis of the comments and feedback through 40 interviews 
  • Validation of targets issued from a market analysis, to allow:
    • A objectives deployment by activity
    • An action plan over the periods to come
  • Building up a Target Model using breakthrough
    • Redefinition of the Make or Buy strategy
    • Re-layout giving preference to FLOW
    • Production Planning based on Pull System
    • Steering based on Visual Management and autonomous units

The driving of actions on the field gave to the project a reality for the staff and allowed to measure the effective feasibility of certain evolutions. 




  • The Target Model responds to the objectives
  • The proposed plan was accepted by the General Management and the Shareholders