Smart operations in the manufacturing sector

A leading aerospace OEM wanted to improve their aftermarket business to increase uptime and parts availability. With cumbersome and non-standard processes, however, they could not connect their spares and maintenance needs to their core business. At the same time, they lacked appropriate tools to see Data in real-time, hampering their efforts to balance their near- and long-term planning requirements.

The solution

Using the connected aftermarket approach, Deloitte Consulting LLP helped to:

• Refine process blueprinting by mapping key aftermarket steps, defining integration points, conducting fit-gap analysis and supporting system changes.
• Gain real-time demand visibility by integrating inventory and field systems for a centralised dashboard, auto-calculating performance metrics and embedding new analytical processes.
• Enhance decision-making by automating repeatable steps, connecting systems to monitor repairs, isolating site and supplier issues and accelerating decisions with Data-driven options.
• Integrate aftermarket with core business by embedding forecasting and demand planning into production Data and establishing a "digital thread" to track supply shortfalls, engineering changes and at-risk demands.

The results

• An improvement of 25% in spare parts availability
• A reduction of 20% in customer wait time
• 2.5 times improvement in forecast accuracy

A leading equipment rental company in the construction, manufacturing and industrial space wanted to modernise their customer service. Due to complex industry dynamics—such as supply chain disruptions, labour shortages and extreme climate conditions—their customers were approaching their operations in new ways. To help customers optimise their productivity, the company wanted to leverage Data-driven solutions to deliver more value through access to fleet management and logistics technology.

The solution

Using the connected aftermarket approach, Deloitte Digital helped design a digitally enabled solution to make equipment rental and management easy and intuitive. Over an 18-month journey, the teams reimagined the equipment rental experience, bringing into a single platform Data and capabilities powered by leading-edge technologies. The new digital platform helps empower customers to capitalise on their own strengths while easily and efficiently drawing from the company’s fleet management knowledge—through rich Data made available in an easy-to-use, mobile-enabled format across the equipment rental cycle. Features include reserving equipment, tracking delivery, monitoring equipment performance, managing equipment operation and having full billing visibility.

The results

• Quarterly growth of 26% in new digital accounts
• Growth of 154% in telmatics alerts
• An increase of 100% in the use of digital service calls

A major aerospace and defence manufacturer was contracted to perform planned modifications to a client’s used aircraft fleet. However, 50% of the required work was not identified or scoped until the aircraft arrived at the MRO facility, disrupting labour, parts and tooling plans.

The solution

Using the connected aftermarket approach, Deloitte Consulting LLP helped them:

• Standardise their planning process based on industry leading practices to enhance efficiency.
• Integrate forecasting into their new planning process by analysing frequent “over and above” work logged in their discrepancy reports.
• Create precedence maps displaying critical paths and resource-loaded crew plans for each scope of work.
• Develop visual management tools that simplified communication between “the top floor and the shop floor” around MRO status, dependant tasks and constraints/needs requiring leader-level resolution.

The results

• Span compression of 30% by optimising planned and unplanned work.
• 25% increase in throughput
• 10-15% margin lift