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
THE IMPACT WE MADE
By combining operational analysis with structural implementation, we helped Air France-KLM Engineering & Maintenance achieve measurable and sustainable improvements.
- Lower inventory costs while maintaining service levels
- Increased throughput and effective shop capacity
- Improved equipment availability through better resource allocation
- Continuous improvement embedded through KPI-driven steering
Facing Similar challenges?
PDM supports asset-intensive, multi-site organisations in implementing uniform asset management approaches that strengthen control and alignment, compliance and operational performance across locations.
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.
