Air France-KLM: Improving flow and inventory management in MRO operations

Improving flow and inventory management within MRO operations

To stay competitive in a demanding MRO market, Air France–KLM Engineering & Maintenance needed to improve throughput while reducing inventory levels without compromising service performance. Internal benchmarks showed high capital tied up in spare parts combined with limited operational flow. PDM partnered with the organisation to structurally improve inventory management, spare part availability and performance steering. Together, we implemented a focused improvement programme that balanced cost, capacity and service levels and embedded continuous improvement in daily operations.

OUR CUSTOMER

Air France–KLM Engineering & Maintenance is the Maintenance, Repair and Overhaul (MRO) organisation of the Air France–KLM Group. Operating in a complex aviation environment, the organisation is responsible for maintaining and overhauling aircraft and components under strict safety, quality and regulatory requirements.

THE CHALLENGE

High inventory levels

Internal benchmarks revealed relatively high inventory levels, resulting in significant capital tied up in spare parts across MRO operations.

Limited throughput and shop capacity

Despite high inventory, maintenance, repair and revision activities experienced constrained throughput, limiting overall operational capacity.

Competitive MRo market pressure

Strong competition in the global MRO market increased the need to improve efficiency, responsiveness and cost performance.

Balancing cost and service levels

Reducing inventory could not come at the expense of service levels, requiring a carefully balanced and structurally embedded solution.

Building excellence together

PDM worked closely with the Lean Six Sigma organisation within KLM as an integrated partner. Rather than delivering isolated improvements, we jointly designed and implemented a structured 3R programme (Right part, Right place, Right time) focused on spare parts and repair operations.

Together, we established a shared way of working that combined analytical depth with hands-on implementation. This enabled the organisation to improve flow and inventory performance simultaneously.

The impact we made

By combining operational analysis with structural implementation, we helped Air France-KLM Engineering & Maintenance achieve measurable and sustainable improvements.

Facing Similar challenges?

PDM supports MRO organisations in structurally improving inventory management, throughput and operational performance while safeguarding service levels.

OUR APPROACH in action

We don’t just add capacity. We embed with client teams to structurally improve operations and ensure changes are sustained in daily practice.

Programme-driven improvement:

Design and implementation of a focused 3R programme addressing spare parts, repair flow and inventory performance.

Data-driven perfromance steering:

Introduction of KPI’s and management systems to support fact-based decision-making and continuous improvement.

Flow and inventory redesign:

Structural improvement of spare part availability and repair flow to balance cost, capacity and service performance.

Hands-on implementation and training:

Close collaboration with operational teams, supported by training to embed new ways of working.

Sustainable ownership and improvement:

Ensuring improvements were not project-based, but structurally embedded in the organisation.

discover our expertise

Design & Engineering

We help manufacturers accelerate complex product development through modular design, scalable architectures, and engineering excellence from concept to integration.