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Critical Chain 2022 International Conference presentation by Philip Marris

Critical Chain in aeronautical maintenance (MRO)

The world of projects when every minute counts


18-19 January 2022

This is the second international conference organized by the official global TOC community association dedicated to Critical Chain Project Management (TOCICO - Theory Of Constraints International Certification Organization).

Critical Chain has enabled thousands of projects to significantly and sustainably improve productivity.  Typical improvements:  25%-100% increase in productivity; durations -20-70%.  And, simultaneously, due-date hits 95% plus. So join us to learn about this approach now used by hundreds of organizations worldwide that enable your projects:

  • To finish on time and in less time

  • To finish within budget and at reduced cost

  • Without any compromise on quality or on initial specifications.


Conference Critical Chain 2022

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Critical Chain in aeronautical maintenance (MRO) The world of projects when every minute counts

By Philip Marris


Critical Chain is already widely used worldwide in the maintenance (MRO) of aircraft whether commercial or military and has produced extraordinary results in Turn Around Time reductions and productivity. We explain why this industry was a pioneer and share the lessons learnt by all the actors these past 20 years.


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Conference summary

Critical Chain is now widely used in aeronautical maintenance (MRO or Maintenance, Repair and Overhaul / Operations). The United States Air Force, the largest fleet of aircraft in the world, is in the process of a global rollout and several airlines have adopted it throughout the world. We start by presenting the list of the over 30 aeronautical MRO cases worldwide from the USA to Australia and from Brazil to France.

We discuss why the fact that it is quite easy to calculate the cost of winning or losing a day in the hangar has meant that this industry is leading the world in the adoption of Critical Chain Project Management (CCPM). In this business they know that gaining an extra day in their Turn Around Time is worth often of the order of $100K. They know better than anyone that time is money (or mission critical for military aircraft). CCPM and its proven results is therefore the obvious solution. 

We share the lessons learnt by all the actors (not just Marris Consulting) these past 20 years:

  • How the starting point is often that there are too many aircraft being worked on simultaneously (not enough focus),
  • Why the planning and scheduling competencies must often be reinforced,
  • How CCPM brings (as usual) exceptional visibility on the progress of each aircraft. Why the availability of the spare parts is (of course) a necessary condition for success,
  • Why using “Work Packages” and 2-tier scheduling facilitates the management of the execution and avoids falling into the trap of micro-management,
  • How the identification of “findings” (unplanned extra work due unexpected deteriorations) become even more critical (because everything else is going much more smoothly),
  • How, as a result, visits are often cut into 2 stages; a first stage where you do whatever disassembly and tests are required to identify any “findings” and a second stage where you do the work,
  • The differences when dealing with recent aircraft versus old aircraft,
  • The limits of CCPM in aeronautical MRO (when the visits are too short and simple to require fully fledged project management). Etc.

We also mention several “common sense” solutions that become even more important when travelling at CCPM speeds such as ensuring that the mechanics always have a “full kit” to do their job (the parts, the tools and the documentation).  


A 30-minute dive into Critical Chain in aeronautical maintenance (MRO). The world of projects when every minute counts. 

Photo Portrait de Philip Marris

Philip Marris Bio

Philip Marris started his Theory Of Constraints (TOC) journey in 1986 when he started working with Eliyahu Goldratt. He founded Marris Consulting in 2003. The companies’ assignments are nearly always TOC based. He has implemented TOC over 270 times in over 25 different countries over the past 30 years. He has for instance assisted: Louis Vuitton, McDonalds, Siemens, GSK, Safran and Ariane rockets. Half of Marris Consulting’s assignments are Critical Chain implementations. He is the author of a bestselling TOC textbook in French. He is bilingual and bi-cultural French/English and lives in Paris, France. Marris Consulting has extensive aeronautical MRO experience: Embraer, Air France, ABS Jets, Dassault,…

About Marris Consulting

Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean, ToC & CCPM training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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