Spitfire

Defence

Reducing aircraft maintenance lead times

Improving operational performance through new ways of working — cutting centre-wing replacement time by more than 30% while improving safety and consistency.

Typhoon jets in close formation
Client
Marshall A&D Group
Sector
Defence
Industry
Military Aerospace
Location
United Kingdom
  1. 01

    The challenge

    • Demand outpaced hangar capacity.

    • Long maintenance turnarounds limited throughput.

    • Centre-wing replacement needed tighter quality, cost, delivery and safety control.

  2. 02

    What we did

    • Applied Lean methods to streamline maintenance.

    • Introduced kitting, specialist tooling and dedicated equipment.

    • Coached engineers to embed Lean and sustain improvements.

  3. 03

    The results

    33wks
    cut from centre-wing replacement time — a reduction of more than 30%
    30%
    efficiency gains, increasing hangar capacity
    Costs ↓
    reduced — while safety and consistency improved
The project has been a resounding success, with Spitfire consultants quickly building rapport, introducing new working practices that reduced lead time by over 30% and delivered cost savings, with benefits spreading across wider operations through a strong focus on implementation over presentations.
Managing Director — Marshall A&D Group

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