“I began working with Kevin Duggan at Sikorsky, where we used his value stream design and mixed-model expertise to create lean flow across Black Hawk helicopter assembly and MRO lines. Unlike past Kaizen-only efforts, Kevin taught principles that reshaped end-to-end material and information flow for the customer. His team worked directly with front-line employees to ensure understanding and application in both back shops and final assembly.”
Traditional MRO (maintenance, repair and overhaul) operations have these traits:
Duggan Associates takes a different approach. We don’t just improve your processes and operations. We transform your MRO systems into self-sustaining, high-performance systems that deliver results, day in and day out.
Duggan has completed MRO projects for aerospace, rail transportation, oil & gas equipment, marine and shipping.
“As part of our transformation journey, we engaged Duggan Associates to guide our lean journey-improving productivity, efficiency, customer and staff experience, and building a stronger culture of continuous improvement.
Their deep technical expertise and industry experience enabled quick wins with tools like Value Stream Mapping, 5S, 3P, standard work, and visual flow.
Their focus on high participation built strong buy-in and a common language across the shop floor. Most importantly, they emphasize sustainable transformation-developing both mindset and capability. I appreciate their close partnership and proactive support.”
TAT is often challenged by due dates complicated by unplanned maintenance work discovered during the normal course of the scheduled planned maintenance.
No matter how short the time for unplanned maintenance, it still can impact TAT and costs.
Duggan helps design systems that make it easier to handle unplanned maintenance work. We look at your system end-to-end to ensure you address all issues and thus eliminating ongoing consulting. Our lean-based systems ensure you have the tools, processes and people to handle unexpected challenges with minimal downtime.
Unplanned maintenance, lack of spare parts inventory control and reactive maintenance strategies are at the core of MRO inefficiencies.
Our expert-led lean training equips your team with step-by-step strategies for immediate results with long-term impact. Duggan designs systems that make it easier to handle unplanned maintenance work without disrupting operations. Our lean-based systems ensure you have the tools, processes and people to handle unexpected challenges with minimal downtime and with little to no management intervention.
With Duggan’s structured approach to MRO, we don’t just identify problems that often require continuous improvement. Instead, we design and implement solutions that propel long-term results. Our hands-on, design-driven methodology is rooted in value stream design, optimizing every aspect of your MRO operations to meet these objectives:
Our MRO training equips your team with the skills and knowledge to implement and sustain improvements for measurable, real-world results making your operation more self-sustaining and delighting customers every time. With Duggan, you get a roadmap for success and a partner who will embed these systems with your employees to ensure they last.
A major MRO needed to cut aircraft check turnaround time (TAT), free capacity for revenue work, and reduce daily firefighting across Base Maintenance, Line Maintenance, and component shops.
“Duggan’s approach is focused on results. We don’t just talk about improving operations. We achieve measurable improvements immediately.”
“70% of tasks now run in continuous flow, creating greater predictability and efficiency across maintenance operations.”
Maintenance, Repair & Overhaul
How the approach works, and what it means for your operation.
Duggan’s maintenance, repair and overhaul experience spans aviation, including helicopters, rail and trains, heavy equipment, and oil and gas. We are also discussing opportunities in maritime MRO. Across these industries, we focus on how maintenance and repair work moves through the operation so teams can deliver equipment back to their customers predictably.
We design how maintenance, repair and overhaul work flows end-to-end, connecting the main operation with support shops, materials and information. The aim is a Customer Delivery System that makes work priorities, progress and interruptions visible, helping your team manage turnaround time and delivery commitments.
The starting point is your equipment, work scope, demand and operating constraints. We examine how jobs move through inspection, repair, assembly and completion, and how they use shared people and resources. The design reflects your operation’s technical and quality requirements rather than applying an aviation workflow to every industry.
The design considers both planned work and additional work identified during inspection or disassembly. Clear priorities, decision points and connections between teams help make the effect of new findings visible, so the operation can respond to changes in scope, parts needs and turnaround time.
We consider how parts, information and support work reach the main operation, including the demands placed on shared resources. Support-shop priorities and delivery expectations are connected to the work they support. Improving an individual shop is evaluated in the context of overall delivery to the customer.
The approach is relevant when work waits for parts, information or specialist resources; priorities change repeatedly; or jobs accumulate without a clear view of completion. We work with your team to understand these connections and design a more predictable flow of work. Measures such as turnaround time, on-time delivery, work in progress and rework help assess progress against an agreed baseline.
Duggan works with your team on implementation and education, so employees understand the operating methods and can sustain them as part of daily work. The design is supported by visible measures, clear responsibilities and management routines that help teams respond when work moves away from plan.
Tell us what equipment you maintain or overhaul, the types of work you handle and where delivery becomes difficult. Useful context includes typical turnaround times, changing work scopes, parts availability, shared-resource constraints and the improvements you want to achieve. We can then discuss where an initial review would be most useful.
Tell us what you maintain or repair, where turnaround time is under pressure and how unexpected work affects delivery. We can discuss how the main operation, support shops, parts and information connect to serve your customers.
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Email thealey@dugganinc.com or call +1 (401) 601-7286 and we'll respond within 2 business days.
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Email thealey@dugganinc.com or call +1 (401) 601-7286 and we'll respond within 2 business days.
