Our pioneering Maintenance, Repair, and Overhaul facility
Where advanced technologies and data-driven insights come together to enhance maintenance, repair, and overhaul (MRO) operations, for increased productivity and performance. Our Smart Maintenance and Repair Facility (SMRF) offers smart and flexible MRO solutions for all types of assets, including aviation, ground vehicles, real estate, manufacturing, maritime, and space, to adapt to change.
Deloitte’s Smart Maintenance and Repair Facility (SMRF) is a client experience and training enablement center dedicated to revolutionising maintenance operations. Located within The Smart Factory by Deloitte @ Wichita, Kansas, SMRF showcases how Industry 4.0 technologies transform MRO processes. Designed for organisations adopting digital solutions, SMRF helps accelerate turnaround time, enhance service levels, reduce equipment downtime, streamline maintenance processes, and digitise operations.
Capabilities at SMRF
SMRF offers a hands on experience, showcasing the latest MRO trends and technologies for smarter maintenance operations.
Optimises work-in-progress (WIP) maintenance by synchronising labor, equipment, and material availability to maximise efficiency. Addresses unplanned downtime, absences, material delays, and emergent work; prioritises tasks; and meticulously manages resources.
Integrates enterprise systems to create a single source of truth and enhances decision-making with real-time data. This approach improves efficiency by allowing data to flow easily across departments and reduces manual handoffs.
Facilitates comprehensive management of the entire product life cycle, from engineering to asset retirement. Enables global standardisation of processes and tools across all sites for design, manufacturing, service, and obsolescence, within an integrated and traceable environment.
Manages MRO activities by executing shop floor work orders, assigning and tracking work in a location, and accounting for material requirements in connection with other major systems. This improves process efficiency, reduces asset downtime, and enhances repair quality.
Describes the scope of work to be completed and replaces traditional paper-based work orders. It is the backbone that enables real-time data collection to support analytics, process, and quality improvement, ultimately enabling broader digital transformation.
Enables seamless asset flow in MRO by autonomously transporting components, reducing manual movement and tracking items accurately. AMRs boost throughput; reduce worker strain; and improve resource tracking, cycle time, WIP, scheduling, and safety.
Captures precise digital models of physical objects for PLM, CAD/CAM, and manufacturing. Integrating 3D scanning in reverse engineering boosts accuracy, efficiency, and flexibility, enabling better product design and streamlined MRO operations.
Enables flexible, low-volume production and customisation, streamlining supply chains with digital inventories and distributed manufacturing. Reduces lead times and complexity, supports new business models, and allows rapid adaptation to market demands.
Provides real-time monitoring and predictive insights on equipment using sensors and cloud computing. PdM enables analytics, alerts, and dashboards to cut downtime, optimise utilisation, and reduce maintenance and parts costs.
Enables experts to see what shop floor workers see in real time, streamlining part acceptance testing. Can be leveraged to provide guided instructions and hands-free training. AR supports remote/AI inspection, quality, and collaborative problem-solving.
Creates a dynamic, adaptable authoritative source of truth (ASOT) integrating technical and business components. MBSE helps visualise interdependencies, reduces risks with digital simulations, enables early testing, standardises management, and streamlines planning.
Provides a holistic view of zero trust compliance across every OT device. Continuous monitoring mitigates threats, supports comprehensive device security, enhances cybersecurity, safeguards critical infrastructure, and fosters a resilient operational environment.
Builds a secure private network connecting operational technology (OT) devices on the shop floor. Protects the broader organisation through a segmented network to which a limited number of people and devices have access, ensuring workers have the technology they need wherever they work.
Takes a big-to-small hierarchical view of maintenance planning, from fleet-level to facility-level to asset-level planning. Data informs each step in the planning process, creating a plan that harmonises long-term planning with daily execution of maintenance tasks.
The SMRF experience: A step-by-step journey
Welcome
This phase introduces SMRF’s modular and customisable experience. Here, we gain a deeper understanding of client needs and provide a high-level overview of our facility’s capabilities, processes, and technologies.
Plan and schedule
The planning phase, spanning from multi-year to day-of execution, occurs at the fleet, facility, and asset levels. Using dynamic scheduling, we visualise and prioritise work in a precedence diagram to simulate the impact of changes in asset or personnel availability.
Induct
MRO organisations often lack visibility into an asset’s maintenance history during induction. Creating a digital thread provides a single source of truth for the entire asset life cycle, enabling a smoother asset induction.
Disassemble and evaluate
As assets are disassembled, additional work may arise. This station links work orders to the dynamic scheduler to help manage critical paths proactively. It also reviews tracking technology options and demonstrates how AMRs (autonomous mobile robots) can automate part transport across a facility.
Repair and overhaul
How does an organisation minimise unplanned maintenance? And when a critical machine goes down for repairs, what should workers do? Through data-driven decision-making, machine condition monitoring (MCM) enables organisations to shift from reactive crisis to proactive maintenance on shop floor equipment.
Validate and reassemble
Quality is a top priority during reassembly, yet many organisations struggle to attract and retain skilled talent. Augmented reality (AR) enables technicians to learn on the job with guided instructions, and remote expert capabilities allow real-time collaboration with experts anywhere.
Command center and cyber
It integrates MBSE for advanced system modeling and cybersecurity monitoring, enhancing operations and security. The command center unifies data from multiple systems for informed decision-making. Cybersecurity provides a secure environment for connected equipment.
Deploy and monitor
We continue the digital thread to capture and analyse repair data, feeding it back into the planning process. This continuous feedback loop enhances repair methods, increases planning confidence, and reduces unexpected variations in future repairs.
