Why Conventional Improvement Strategies Don’t Work for MRO Component Shops

We’ve frequently visited MRO component shops for work, and we are often struck by how modern, high-tech shops struggle to fit their complex and variable processes into standardized procedures. Many shops yearn for long-term, flexible solutions. However, conventional methods for process improvement—often designed for high-volume, low-variation environments—are being forcefully implemented to address MRO shop challenges. These methods are known for their systematic approaches to identifying and removing process inefficiencies, but they often fall short in dynamic and unpredictable settings like MRO maintenance.

MRO Shop Maintenance: Not Your Average Industry

On the surface, traditional improvement methods might sound ideal for any business looking to streamline operations. But in the aviation industry, especially in MRO shops, these rigid frameworks often miss the mark. MRO shop tasks are rarely straightforward and involve far too much variability to benefit from inflexible methodologies. Through firsthand experience, we’ve seen these initiatives fail to deliver results because of poor project management, changing project scopes, and insufficient support from executives.

Another major challenge is the time factor. Many of these improvement systems are heavy and slow-moving, requiring a significant investment of resources before any results are seen. In MRO, a fast-paced environment with urgent demands, quick results are essential. After years of research and analysis, we believe that the real solution for MRO shops lies in a more adaptive approach—one that is both responsive to change and quicker to implement.

Your Team: The Key to Successful Implementation

Yet, despite these challenges, MRO shops worldwide continue to invest in conventional training and methodologies, working alongside quality departments and allocating substantial budgets to improvement projects that may not yield desired results. The outcome? A cycle of high costs without lasting impact—a waste of both time and money.

So, what can break this cycle and create meaningful, sustainable improvements? The answer lies in focusing on flexibility and fostering motivation across all levels of the organization. When every layer of the team understands what results are expected and how their efforts contribute, the likelihood of success grows. Flexibility and continuous change are possible when every team member is invested in the outcome.

“NEITHER MONEY NOR TIME—YOUR OWN TEAM IS THE KEY TO SUCCESS”

In Conclusion

Leave behind traditional improvement frameworks and look to proven improvement concepts tailored for MRO’s unique demands. With these adaptable approaches, your shop can achieve a  reduction in Turn Around Time (TAT), increase in customer satisfaction, and reduction product defects.

Combining practical knowledge with the insights of the people on the shop floor, you’ll have a winning formula for successful process improvement. Whenever we visit an MRO component shop, we rely on the technicians to provide an accurate picture of the current process. These seasoned maintenance professionals know what works—and what doesn’t—in a way that no monitoring tool can replicate.

At HACE, we firmly believe that success lies within your own organization. Achieving improvements depends on overcoming the biggest barrier to change: staff acceptance. When you listen to your team and empower them to lead in process improvements, resistance to change fades away.

Need Help?

Together, we can work on practical, team-driven improvement processes that engage every member of your organization. From management to the workforce, we can guide your team to spot improvement opportunities and achieve lasting results.

Feel free to reach out with any questions at +31(0) 20 894 64 90 or email: info@hace.aero.