A global aviation MRO provider planned to introduce a new product line alongside its existing three but faced significant spatial and logistical constraints. With demand expected to rise across all four product lines, leadership needed a complete facility redesign that would sustain five years of growth without additional expansion. Long repair part lead times reinforced the need for a more efficient storage solution, but the company lacked internal continuous improvement expertise.

Adonis Partners stepped in to conduct an in-depth assessment of the client’s operations, focusing on process efficiency, storage optimization, and production flow. To build internal capability, consultants provided Lean Six Sigma Yellow Belt training and certified key personnel. After evaluating multiple layout scenarios, Adonis developed 16 feasible facility designs that improved service, storage, and production capacity while allowing for long-term scalability. 

The final recommendations exceeded the 2029 forecasted demand, vastly increasing production bay capacity with 9 new bays and raising storage capacity by nearly 65%. Three existing cranes were utilized in the redesign, skirting costly equipment relocation and expansion expenses. Adonis’ work to leverage existing infrastructure and optimize workflows established a flexible, high-capacity operation designed for efficiency.