Success story · Aviation MRO · FactoryBooster
When one productive shift left the next two struggling
At an aviation MRO workshop, one shift’s strong output could leave the next two struggling. Choosing quick jobs and reducing setups improved local results, but filled buffers and pushed difficult work into later shifts. FactoryBooster helped coordinate work across shifts, aligning individual priorities with overall throughput and delivery.
%
of workshop capacity freed
Goals
- Turn the workshop’s available capacity into dependable throughput and on-time delivery.
- Coordinate work across stations and shifts so that one team’s progress supported the next.
- Keep needed parts moving while controlling work in progress and pressure on buffers.
- Give technicians clear priorities and an understandable reason for the work sequence.
Challenges
- Good local results hid a costly imbalance. Selecting short jobs and minimizing setups improved one station’s figures while leaving later shifts with longer jobs and more demanding changeovers.
- Work accumulated in the wrong places. Some downstream buffers needed temporary extra storage, while other stations waited for parts belonging to orders approaching their delivery dates.
- The pattern disappeared across shift boundaries. Limited information exchange and complex production routes made it difficult to connect one shift’s choices with another shift’s difficulties.
- Moving bottlenecks complicated the diagnosis. Product mix and planned or unplanned maintenance changed the constraints, making the effects of work selection harder to isolate.
Solution
- The investigation connected the shifts. Interviews with operators from different departments and their managers revealed how work was actually selected—and why a good run could be followed by disappointing performance.
- Every shift received a clear work sequence. FactoryBooster indicated which orders to process and in what order, helping resolve the imbalance created by local job selection.
- Priorities connected the handover. Work selection accounted for downstream needs and the jobs left for subsequent shifts, bringing individual station activity into line with overall delivery priorities.
- Technicians could see why their contribution mattered. A clear briefing connected the work sequence to workshop throughput and on-time delivery, making the purpose of the change understandable.
Does a strong shift always lead to a strong day in your operation?
Bring us a case where local productivity and overall delivery performance tell different stories. We can explore which constraints and work priorities your production plan needs to connect.
Result
Coordinated scheduling across shifts reduced work in progress and helped the workshop meet expected turnaround times in almost all cases—a marked improvement over previous performance. The improved production flow freed up 18% of workshop capacity.
Your Contact
Carlos Ayala Jiménez
Phone: +49 1516 2 60 74 21
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