Enabling Lean MRO

Culture change

To achieve the success that will only come with process optimizations and culture changes, MROs must implement the IT designed specifically to support lean MRO operations. Today, success in MRO operations is no longer about simply turning wrenches. It is now all about the tooling that provides reliable, just-in-time information to MRO decision makers.

Software solutions

Any suite of MRO software solutions should provide maintenance and engineering organizations with the planning, execution, analysis, and reporting solutions required to drive the following lean/Six Sigma initiatives:

• Detailed event planning and execution for heavy, shop, light, and line maintenance actions
• Robust data capture, analysis and reporting for metrics-driven continuous improvements
• Optimal task assignments and material tool allocations
• Real-time status internal/external communications
• Maximization of mechanics’ time on assigned tasks
• Integrated analysis of reliability information from aircraft, legacy, and execution information

IT integration

A common problem in achieving a truly lean MRO operation is a less-than-comprehensive/complete lean transformation. Even though MROs spend millions of dollars to transform their facilities into lean machines, many efforts fail because of a lack of effective IT integration throughout the operation.

In other words, ineffective and nonuse of IT systems to enable and support lean methodologies are the two main reasons for lean-implementation failure.

An effective lean IT solution is integral to capturing, managing, and accessing the comprehensive and highly accurate set of information applicable to lean MRO processes and assets. Once this information is collected, it must provide enterprise leadership with the core knowledge needed for effective decision support across the entire product lifecycle. This knowledge can then be leveraged in work flow-driven processes which, in turn, can be tightly focused to achieve metrics-driven lean/Six Sigma MRO objectives.

In closing, lean MRO is a holistic, comprehensive, enterprisewide program designed to be integrated into the MRO’s core strategy as an aid to operational transformation. The lean MRO’s IT solution enables MRO/Six Sigma strategies by doing all of the following things well: Ensures repeatable processes and systematically provides micro visibility to movement of assets (including technicians) in a cost-effective manner; guarantees both reliability and readiness; and reduces turnaround time (TAT) and cycle time with accurate forecasting of resources by providing just-in-time knowledge. 

Dinakara Nagalla is chief executive officer and president of EmpowerMX. EmpowerMX provides aircraft maintenance software and consulting services to the air transport industry. For more information visit www.empowermx.com.