Plane in the sky

Major Flag Carrier – Engineering Hangar and Headcount Efficiency

The challenge

Nyras conducted a review of a major flag carrier’s line maintenance, hangar efficiency, and Part M organisation in order to improve profitability and help plan for future growth.

Key objectives of the project were to: 

  • Produce recommendations to improve productivity.
  • Suggest efficiencies to optimise manning levels.
  • Determine the most efficient and cost-effective use of the existing hangar area.
  • Develop Part M cost benchmarking.
  • Provide gap analysis of the AMOS system used by team.
  • Review Part M and Part 21 Design Organisation Approval (DOA) functions and how they are accomplished.

The solution

Nyras worked alongside our client’s engineering and maintenance team, taking a hands-on and open approach to review current practices and suggest improvement.

We completed a comprehensive review of workload capacity and compared it to actual manpower availability to develop recommendations that addressed the ‘gaps’ and improved productivity. We also reviewed the current maintenance plan to establish any efficiencies that would benefit the operation and optimise manning levels.

Every area of the business was assessed, including job recording techniques used within the hangar, where we suggested improvements to maximise productivity. With our comprehensive and thorough approach, we were able to determine the most proficient and cost-effective use of the existing hangar area.

In addition, we reviewed the airline’s Part M engineering support department to assess the maintenance planning functions, including the interface with the Part 145 production planning department. We presented the client with a detailed review of the Maintenance Planning Document (MPD) and additional non-MPD tasks including:

  • Maintenance check performance data focusing on the defect man hours and scheduling of tasks.
  • Indirect headcount deployment by location and role across both Part M and 21.
  • Detailed analysis of how Part M and Part 21 DOA functions are carried out.
  • Part M cost benchmarking.
  • Gap analysis of the AMOS system used by the airline.

The results

Using findings from our research, Nyras proposed labour efficiency improvements, the insourcing of heavy maintenance checks, optimisation of maintenance events performance and a reduction of tasks in order to maximise competency across the business. Total profit improvement opportunities of €4.2m per annum were identified and agreed with the airline’s management.

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