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A jet aircraft maintenance, repair, and overhaul (MRO) facility located in southeast Florida had developed a reputation of delivering poor quality and not meeting customer delivery dates. Consequently, the volume of business dropped, and margins had eroded. The MRO facility retained a smaller segment their conversion business, but the maintenance and repair side of the business was effectively eradicated.
A two-week Assessment was performed in May of 2017 with the following findings.
An Improvement “Road map” consisting of three (3) workstreams was developed to address the issues confronting the organization. Organizational Development (including the Culture), Planning & Scheduling and Shop Floor Management (including Quality) covering a 26-week period.
The Organizational Workstream revised the organizational structure with clearly defined Roles, Responsibilities & Accountabilities. Developed with each level of the organization a “Cadence” aligning their behaviours with their accountabilities, then coached and mentored the transition. In addition, the organization was aligned on specific Corporate Goals with specific Strategies for accomplishment.
The Planning & Scheduling workstream facilitated the revision of “Task Cards” into manageable work steps of less than 40 hours, created “Standard Task Cards” to eliminate redundant activities, and segregated the tasks by craft and section of the aircraft to enable effective scheduling. Planners were aligned with the Project Managers to maintain the project schedule, reviewing its weekly with the Director of Operations, revising it and then generating “Daily Shift Schedules”.
Shop Floor Management Workstream addressed floor short interval management through solid work assignments and follow-up. Applied 6S to the shop floor to eliminate the hours of wasted labour collecting materials and tooling at the start of each shift. Developed and installed First Pass Quality Metrics. Implemented a partnership culture between Quality Inspectors and Operations. Deployed Shop Floor Metrics (SQDCP). Coached and Mentored Operations Management & Supervision in alignment with their respective Cadences.
Representative bottom line accomplishments include: