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Rakesh Kumar Singh Written by Rakesh Kumar Singh, Senior Design Engineer - Aftermarket
on 02 May 2022

The global maintenance, repair, and overhaul (MRO) market is valued at $622 billion. This figure is especially staggering considering it is further expected to grow over the next five years. MRO and service center networks refer to all maintenance activities that ensure the safety and airworthiness of aero engines that come in for repair and scheduled maintenance. The maintenance and upkeep of these activities is especially crucial when considering flight safety, passenger comfort, and a wide range of other factors to ensure top condition of aero engines.

One of the biggest challenges for original equipment manufacturers (OEMs) is to coordinate between multiple service center networks and MRO to forecast engine shop visits and confirm availability of parts. The complexity and global scale of the MRO/service center network value chain demand a better system that helps plan and manage shop visits. The current practices are heavily dependent on service center networks to receive and validate the data, handle the delay, and control the delay in change request. The entire process is performed manually using tools such as Excel sheets. These result in time delays that can easily set back the entire value chain. The independent operations of service centers and variations in response times often result in rework before a final scorecard can be released.

Apart from the basics, there are additional challenges that OEMs face:

  1. MROs and service center networks are not connected and do not maintain data. Thus, validating data becomes time-consuming, resulting in delays in forecasts.
  2. Delay and manual validation results in indecisive performance indicators.
  3. Errors in key attributes result in misleading forecasting that has financial impact.
  4. Decision-making is affected as frequent changes require going through the entire manual process repeatedly.
  5. Rework entails time and high costs.
  6. Delay in publishing the final report.
  7. Storing and managing the data manually in Excel sheets is tedious and time-consuming.
  8. Rework is foreseeable and cost-ineffective.

Overcoming these challenges is imperative and Cyient embarked on finding a technology-led solution that can help with better planning and forecasting of shop visits.

Cyient approached this problem with a digital solution mindset, with a transformation tool in SQL with three matrices (Planning, Operation, Actual). The solution created a new shop visit counting rule and validation reference points to transform and implement. All key performance indicators were developed in Web-designed dashboards, and reports were integrated with auto Power BI interface, without any manual intervention.

Cyient’s transformation tool meets all the business rules and logic to validate duplicates, shop continuation, work scope change, re-induction, and timely indication if there is a change from the initial work scope. Its objective is to provide all metrics as per customer requirement. It also provides a master consolidated list on forecasting, inventory management, and the shop floor planning team. The data is used to create scorecards, performance metrics, induction and shipment metrics, technical report escalation, and updating the main aircraft/engine database. The tool generates multiple reports according to different programs, different service center networks, and work scopes. It fulfils the requirements of OEMs and different networks without any manual intervention.

By deploying tools of process mapping, value stream mapping, SQL, and value proposition canvas, Cyient’s engineering team was able to ensure complete end-to-end optimum quality to ensure highest possible forecasting and shop floor management (planning, induction, change request, shop floor availability, baseline for financial impact, and shipment). A single master database with a 360-degree view for the service center network helps mitigate manual work and enhances product quality.

Cyient’s solution delivered tangible impact:

  • Good connectivity with the implementation of the new tool reduced TAT by 20%
  • On-time delivery increased by 100%
  • Multiple data points were converted to a single portal which reduced rework and resulted in productivity saving

The advantages of the solution were manifold:

  1. Single portal to maintain the master data and present wide variety of metrics (dashboard)
  2. Self-use by all departments at any location
  3. Self-service without dependency
  4. Ability to adopt quick change request
  5. Auto-generation of reports in Power directly from portal
  6. Digital dashboard with filters to manage metrics
  7. Monitoring and controlling ability from a single point
  8. Time reduction, enabling large data processing
  9. Zero waiting time for the report for quick decision-making
  10. Single, cost-effective solution for multiple document types

With a technology-agnostic and operations-focused approach, Cyient’s first proof-of concept was launched to create an innovative digital experience for shop floor management. This was followed by the successful launch of the digital version of the aftermarket planning tool.

Integrating the entire process digitally is vital to retain competitive advantage and can act as a catalyst for improvement at every level of the organization. Effective digitization strategies help business intelligence to simplify the information flow to the individual/organization. The benefits of such a solution are immense, where even the smallest improvement in operational standards means saving millions of pounds in efficiencies.

Cyient’s expertise in the aerospace and MRO industry helped us identify a gap in the market that a technology-led solution could address. The ROI on the solution was tangible and immediately visible. Most importantly, it helped address a problem that was currently being approached in an antiquated manner. If you would like to see how Cyient can help your aerospace and MRO business, reach out to us or visit our website: Aerospace Defense

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