Operational Improvement

We help clients achieve best-in-class performance through insights and deep experience.

CAVOK’s proven approach starts with a health assessment of the client’s organization, using our proprietary Rapid Assessment Framework (RAF) to guide the evaluation and develop an implementation road map for areas needing improvement. Our team members then provide implementation support using Continuous Improvement (CI) methodologies and tools. Our in-depth knowledge of Lean, Six Sigma, and Theory of Constraint (TOC) enables us to quickly and efficiently deploy those best suited to help our clients build a world-class operation.

CAVOK’s CI practice offerings range from executive-level strategic action and communication workshops (covering alignment of organizational goals, objectives, and KPIs) to continuous improvement systems and we promote employee engagement at all levels and cultural acceptance in the CI process.

Organizations often struggle to efficiently manage large scale CI project initiatives, so CAVOK offers a turn key Project Management Office (PMO). Our established PMO procedures align with Project Management Body of Knowledge (PMBOK) requirements for critical path, communication plans, and risk identification/mitigations and our team provides real-world experience, insightful analysis and recommendations to help clients implement essential projects successfully.



  • Continuous Improvement
  • Health Check
  • Lean Manufacturing
  • Lean MRO
  • Process Improvement
  • Rapid Assessment
  • PMO
  • Project Management
  • Six Sigma
  • Solution Definition
  • Theory of Constraints

The Situation

A major US-based engine MRO wanted to expand its overhaul production system into commercial MRO services.

The client’s legacy military engine production system was not designed for the repair-intensive overhaul processes common in commercial engine production.

Supply chain, engineering, and other production support functions weren’t set up for commercial engine production.

The plant’s production lines needed modification to implement a military/commercial production system.

Equipment, tooling, warehousing, parts tracking, and other internal issues had to be addressed for commercial engine production.



Using its Rapid Assessment Tools, CAVOK conducted a plant-wide assessment and developed a detailed project plan for the facility’s expansion into commercial engine production.

The initial assessment produced an itemized list of issues that had to be addressed before building commercial engine capability into the plan.

This list of prioritized steps and timelines formed the skeleton of the project plan.

CAVOK led the implementation of major elements of the plan, including plant layout redesign, external supply chain operations, materials (kitting and logistics), production metrics, and repair process development.



CAVOK led the eight-month implementation project, with CF6-80 production capability established two months ahead of schedule. The project included:

  • Fully developed repair programs
  • Test cell certification
  • Kitting and parts flow management systems
  • Supply chain support initiatives
  • Redesigned disassembly, repair, and assembly cells

Bottom Line

Replicating the CF6 project plan, the client’s internal teams established CFM56 capability about a year ahead of schedule.




Operational Improvement Insights

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