Reducing Engine Repair Cycle Time and Generating $369K in Savings
The Challenge
The existing repair workflow lacked standardization, clear accountability, and effective coordination between inspection, repair, and testing stages. Variability in execution and handoff delays contributed to a cycle time far longer than required, limiting capacity and increasing cost per unit.
Impact
- Excessive cycle time slowing engine throughput
- Higher labor and overhead costs
- Reduced operational efficiency
- Delayed delivery schedules
- Lost savings opportunities due to process waste
Solution
The project focused on analyzing the end-to-end repair workflow, identifying bottlenecks, and implementing targeted process improvements. Key actions included streamlining inspection steps, eliminating redundant activities, improving scheduling alignment, and establishing clearer process ownership.
Outcome
The optimized workflow reduced engine repair cycle time by 57%, unlocking significant operational efficiency. Over a two-year period, the improvement generated $369,000 in measurable cost savings, strengthened throughput capacity, and improved delivery reliability.
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Our Approach
The Results
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