How a leading aerospace MRO shop cut part shortages by 73% during a ramp-up
To leverage its data and simplify its daily routines during a steep ramp-up, this industry-leading MRO shop used Pelico’s Manufacturing Orchestration Platform. Within 11 weeks, it cut part shortages by 73% and WIP by 18%, raised team productivity by 80%, and reached a 97% user adoption rate.
The starting point
Year-over-year growth
25%
Daily updates to WIP status
50+
Of delivery delays due to part shortages
64%
Of revenue blocked by part shortages
37%
Challenges
The challenges
The shop was growing quickly, and daily supply chain disruptions hindered its performance: late supplier deliveries, part shortages, quality issues, and specific customer requests. Before starting its journey with Pelico, the shop was struggling with 182 missing parts for service orders. Part shortages caused 64% of delivery delays and blocked 37% of revenue.
- Teams living in a parallel universe of spreadsheets had less time for value-added tasks, which affected supply chain performance.
- Limited insight into factory forecasts and performance lowered overall productivity and led to costly last-minute solutions.
- Inaccurate and siloed data increased part shortages, which delayed customer deliveries and cost revenue.
- Teams were forced into firefighting mode, which created high stress levels and led to sub-optimal manpower performance.
Objectives
The objectives
The shop wanted accurate data in one place, so its teams could spot part shortages earlier and step out of firefighting mode.
- Identify the levers to optimize the shop’s operational routines by giving teams access to accurate data, to reduce part shortages.
- Centralize the data in one platform to improve factory operations and reduce WIP and time spent on low value-added tasks.
- Identify improvement opportunities to detect part shortages earlier and minimize firefighting.
- Enable streamlined, data-driven decisions and cross-functional collaboration to improve overall operational performance.
The Fix
The fix
The shop’s operations ran on team routines that all required access to data. To find the levers to optimize them, Pelico mapped the existing processes by shadowing users. Pelico’s Manufacturing Orchestration Platform was then implemented to support those routines, giving all teams a single source of data. Because the MRO team could keep its existing processes while using Pelico, adoption went smoothly.
- Solution: MRO
- Scope: one MRO shop
- Teams: MRO planning, production control, supply, and customer service
- Timeline: results within 11 weeks
The results
Customer OTD
+15%
Turnaround time
-37%
Part shortages
-73%
WIP
-18%
Team productivity
+80%
User adoption rate
97%
Within 11 weeks, the MRO shop achieved significant improvements. Team productivity rose by 80%, and a 97% user adoption rate strengthened cross-functional collaboration and data-driven decisions. Daily routines took 10 minutes instead of 2 hours per perimeter, with one tool instead of six, and finding a mitigation for each bottleneck took 5 minutes instead of 18.
Simplified daily data routines and cross-team collaboration changed how the shop runs, making accurate data the driving force behind daily decisions and overall performance.
See what Pelico could do for you
Wondering how Pelico could help your operation? Read the full case study (PDF), or bring your operational reality to a demo.
