The airline had initiated a process optimisation programme across its major technical hubs in three key cities, aiming to standardise operations and enhance maintenance productivity. Through an in-depth analysis of work processes, the organisation gained valuable insights into reducing variance in flight execution by obtaining a robust and productive maintenance production. Valcon’s Toyota-trained lean coaches coached lean leadership behaviours and mindset on a technical basis and assisted with the implementation of lean tools such as visual management, standard calendar, manpower planning and standard work.
The technical division has seen a productivity increase of 25%, which contributes with an annual SEK +50 million to the ongoing cost reduction programme through improved work procedures, management structures and task management of maintenance tasks. Notably, the program led to a 25% decrease in unplanned operational downtime, a 50% reduction in repair time, and a 40% decrease in time allocated for scheduled maintenance tasks. The internal team was left capable of managing similar initiatives independently and has started applying the learned methodologies to other functional areas.
The net impact amounted to significant annual cost savings due to process standardisation and targeted activities aimed at enhancing productivity.