Case Study: Major European Airline Group achieves €7.2m annual heavy maintenance savings with PA Consulting

Major European Airline Group - Customer Case Study

PA Consulting worked with a Major European Airline Group to review heavy maintenance provision across five airlines operating 165 aircraft. The group was managing maintenance independently across its brands, leading to sub-optimal planning, low productivity in its in-house facilities, and high outsourced maintenance costs. PA Consulting was engaged to develop a business plan and maintenance cost model to optimise heavy maintenance spend.

PA Consulting analysed maintenance planning, work practices, procurement, and workforce efficiency, then built ten-year maintenance scenarios and a detailed cost model to identify the best future operating setup. The recommended changes led to consolidation of heavy maintenance in the UK, closure of the German facility, new annualised hours and staffing arrangements, and outsourcing to LHT’s Eastern European base. The program delivered annual savings of €7.2m, or about 40% of annual heavy maintenance spend.