ABSTRACT
This was an unusual case study for me for an assortment of reasons. One of the primary reasons was my absolute lack of experience in engine overhaul technology. Because of this, I spent the first several weeks just analyzing and learning the Engine Overhaul Process at this location. Once I was comfortable with the engine overhaul process, I developed a comprehensive process map, outlining all the required steps for completing this process and then developed a series of causal chains and sub-process maps to better understand why things weren’t operating as they should be. Because the engine overhaul process cycle time is much longer than planned:
Costly rental engines remain on the aircraft much longer than the budgeted time: the estimated loss/OH is ~$10,000.
Significant parts discounts from DAI cannot be captured: the estimated loss/OH is ~$9,500 for new parts and ~$6,700 for serviceable parts for a total of ~$16,000.
