“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.”
We don’t just assess your processes. We design an MRO system with your team that eliminates inefficiencies, sustains itself and ensures long-term success by analyzing the process from end to end.
The size of an operation is not a challenge. Duggan’s methodology works for any size operation because it always approaches challenges from end to end. Our structured tactic applies to any size operation, ensuring scalable, repeatable and efficient processes.
Many clients experience significant improvements within weeks, with lasting transformation as new processes take hold.
We help companies implement predictive maintenance, optimize repair schedules and manage spare parts properly.
Business should consider current maintenance costs, downtime impact, availability of skilled personnel and investment in new technologies.
