Production processes

Production processes

Engine maintenance, repair and overhaul (MRO) is a highly complex task that poses special challenges for any MRO shop – from teardown, assembly and parts repair all the way to logistics and supply chain management. To ensure that the work flow is smooth and fast, the individual steps in the maintenance process need to be perfectly aligned with one another.

To overcome these challenges, MTU Maintenance has developed MRO InTakt, a smart production and control system. MRO InTakt provides for optimally coordinated and well-timed processes in the shop and the supply chain to make sure the requirements for each individual engine are met. This results in shorter and highly predictable turnaround times – also assisted by lean production processes and just-in-time parts provisioning and supply.

MRO InTakt aims to achieve a continuous flow of the process steps according to the “pull” principle, with specific "takt" times having been established. A sophisticated production control system ensures that the capacities necessary to carry out sub-processes, such as parts repair, can be determined early on and adjusted to match actual demand. This way, MTU Maintenance has established a highly standardized process that ensures high predictability of turnaround times and enables the company to respond very flexibly to individual requirements.

MRO InTakt

Within MTU Maintenance, a standardized production and control system based on a consistent shop floor management process has been put in place. As part of its continuous improvement efforts, MTU Maintenance is always looking for ways to optimize the process.

For example: production was further improved through the incorporation of principles from the automotive industry:

  • The work flows in the shop and in the supply chain are brought in sync with one another in line with the requirements for each individual engine, with specific takt times having been established.
  • Continuous flow of the work according to the “pull” instead of the widely used “push” principle
  • The sophisticated production control system ensures that capacities for sub-processes can be determined early on to optimize takt time, so that potential bottlenecks are identified and eliminated before they become a problem.
MRO InTakt, MTU Maintenance's production and lean management system bases on four pillars:
Flow principleTakt principle Pull principle Zero PPM principle
Realization of flowline production by coupling and streamlining of processes Harmonization of processes to achieve a stable and balanced production rhythm Parts are passed on only if required for the downstream process Continuous improvement and stabilization of all processes


The production system as such varies with the size of the facility and the local customer requirements. MTU Maintenance Hannover, the largest of MTU’s maintenance companies, converted to the flowline principle ten years ago. MTU Maintenance Berlin-Brandenburg operates a CF34 flowline. The flowline principle allows high throughput rates to be achieved with a minimum space required, with different engine types being simultaneously cycled through the shop.

The facilities in Canada and China work according to the traditional dock principle, which allows highly individual workscopes to be optimally handled. Such workscopes are typically encountered with older engine types, such as under the MTUPlus Mature Engine Solutions program.

It goes without saying that MTU Maintenance is looking to continuously improve its production processes. At the moment, an initiative dubbed Operational Management is underway, its aim being to introduce a new production system that allows daily control and adaptation. It is based on a daily target-performance comparison of the progress of the work on each individual engine in the shop from which corrective actions can be derived.

Customer benefits

  • High quality standards through standardized basic processes
  • Smooth cycling of the engines through the shop without any waiting times
  • Shortened and highly reliable turnaround times
  • Flexible production to suit individual requirements