A large domestic airline's new maintenance facility was not delivering the value it needed to compete.

Processes were inefficient, and the airline needed better critical path management to reduce visit costs for its 737 fleet amid tough competition.

• Gathered ideas from managers, team leaders and leads on every shift to remove non-value-added work
• Prototyped the new process in a single maintenance bay before rolling it out facility-wide
• Added visual management and upgraded management skills through training and floor coaching

Best practices were then rolled out across the airline's other maintenance operations.