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Representative illustration: One of the world's largest helicopter fleet operators needed better availability and dispatch reliability to win and keep business.

Case Study · Aerospace & Manufacturing

One of the world's largest helicopter fleet operators needed better availability and dispatch reliability to win and keep business.

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1Challenge

Maintenance was being centralized, but hangar supervisors still worked reactively. Weak production control, no long-term planning and base-to-base conflicts caused material shortages.

2Approach

  • Mapped planning, 24/7 hangar execution and material logistics to find and rank process gaps
  • Ran joint USC–client teams on 11 key areas using project charters and kaizen
  • Set baseline KPIs and tested each solution in the hangar before rollout

3Results

90%

Reduction in penalties

85%

Reduction in buy-backs

6%

Better aircraft availability and dispatch reliability

40%

Better weekend cycle-time attainment

Customers who usually called to complain called to note the improvement.

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© USC Consulting Group 2026 | Aerospace & Manufacturing. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.