How an aerospace MRO shop in Asia-Pacific absorbed a 23% repair order ramp-up without additional resources
To absorb a steep repair order ramp-up (+23%), this aerospace MRO shop used Pelico’s Manufacturing Orchestration Platform to leverage its data. Its teams cut turnaround time and part shortages, and improved cross-functional collaboration and data-driven decisions.
The starting point
Repair order ramp-up to absorb
+23%
Blocked WIP
92%
On-time delivery
-15%
Below target
80%
Challenges
The challenges
This MRO shop was running its operations under pressure: a production and supply chain environment paired with a 23% ramp-up, and a growing backlog. Daily disruptions hindered shop operations and affected supply chain performance. Teams pieced together data from spreadsheets and ad hoc dashboards to adjust repair planning, which made every disruption harder to handle.
- 70+ missing purchase orders and manpower shortages disrupted daily operations, causing significant delays and inefficiencies in the MRO shop.
- More than 700 past-due service orders in customer hold, and siloed data, disrupted productivity and made team alignment difficult.
- Longer turnaround times led to significant penalties for late deliveries, a longer backlog, and decreased customer satisfaction.
- Tedious, repetitive spreadsheet maintenance led to unforeseen supply chain disruptions, forcing teams into reactive firefighting mode.
Objectives
The objectives
The shop needed every team working from the same data, with less time lost on daily reporting. The goal was to spot bottlenecks early enough to prevent part shortages, and to move teams out of firefighting mode.
- Align all teams on a single source of data, cutting the number of tools from 5 to 1.
- Anticipate bottlenecks early to eliminate part shortages and increase production.
- Make decisions faster by spending less time on daily reporting.
- Streamline cross-team collaboration, so teams can move out of firefighting mode into a less stressful environment.
- Easily analyze the impact of alternative repair plans to improve supply chain performance and customer satisfaction.
The Fix
The fix
The shop deployed Pelico’s Manufacturing Orchestration Platform for its MRO operations, giving all teams a single source of data. Pelico was implemented to support the productivity of the shop’s daily routines, from updating the WIP report to crisis meetings and tiered meetings. Because all teams could keep their existing processes, adoption was fast and smooth.
- Solution: MRO
- Scope: one MRO shop
- Teams: planning team first, then cross-team, with management training and a first cross-team training
- Timeline: the planning team got value after one week; results within eight weeks
The results
Coverage rate by service orders
+8pp
Productivity
+20%
Saved per day by Pelico users
2 hrs
Usage within 5 weeks
x5
Daily users after one month
39
Within just eight weeks, the shop achieved substantial improvements. After one week of use, the planning team was already getting value from the platform. Daily reporting went from 2 hours to 5 minutes, and from 5 tools to 1.
A 23% faster routine completion let teams absorb the steep ramp-up without additional resources. Progress in data management and cross-team collaboration made accurate data the foundation for daily decision-making 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.
