Challenges for MRO Shops: Complexity, Incompatibility, and a Lack of Synergies
An international manufacturer of aviation propulsion and power systems faced the challenge of making its MRO facilities across multiple locations more efficient, flexible, and future-proof. Differences in processes, tools, and organizational structures currently hinder cross-site collaboration, prevent synergies, and lead to unnecessary complexity.
The goal of the project was to develop a standardized yet adaptable blueprint for DAT (Disassembly, Assembly, and Test) operations—with the aim of increasing productivity, reducing errors, and laying the groundwork for future investments.
Innovation Cell as a Methodological Booster
Together with a cross-location team, we implemented an “Innovation Cell”—a structured, collaborative, and behavior-oriented approach to innovation based on in-depth analysis, creative concept development, and systematic evaluation. This approach made it possible to develop viable solutions in eight days and assess their potential impact.
Four Leverage Points for Future MRO Shops
To create a highly flexible and efficient MRO shop, the focus is on a blueprint that leverages four transformative levers:
- Standardized platform architecture: From shop floor design to skill levels—standardized on the outside, flexible on the inside.
- Modular Workplace Design: Reducing complexity and increasing flexibility through cross-skilled teams and modular workstations.
- Digital Solutions: Joint development and implementation of digital tools to support processes and prevent errors.
- Standardized Processes & Workflows: Consistent procedures, simplified workflows, and fewer sources of error across all locations.
Thanks to the structured approach based on the Innovation Cell methodology, concrete, quantifiable solutions were developed. This not only ensures the long-term viability of the MRO shops but also makes a sustainable contribution to the company’s overall performance.
Expected Impact – A Blueprint for the Future
The four system concepts developed—Greenfield Entry, Greenfield Target, Brownfield Entry, and Brownfield Target—form the basis for a phased implementation of the “trusted MRO” strategy. Here, “trusted MRO” refers to an organization that reliably meets individual customer requirements while utilizing state-of-the-art technologies and ensuring high scalability and efficiency through standardized processes. The concepts developed already show promising potential:
- An expected productivity increase of approximately 15% for the target systems
- Reduced error rates and streamlined processes through consistent standards
- Greater flexibility through modular and cross-qualified structures
Together Across Borders—A Project That Brings People Together
A standout feature of this project was the intensive and trusting collaboration across locations and cultures. Employees from Europe, Asia, and North America contributed their expertise, perspectives, and experiences to jointly develop a forward-looking solution for the MRO organization. The Innovation Cell served not only as a methodological framework but also as a catalyst for genuine collaboration. Through open dialogue, mutual learning, and a shared commitment to excellence, a strong network emerged that extends beyond the project itself. This form of collaboration impressively demonstrates how global teams can achieve extraordinary results through shared goals and mutual respect.
