Helping MRO Operators to Go further.

Develop Consulting are improvement experts working with Maintenance, Repair and Overhaul (MRO) operations, along with linked partner and supply chain organisations, to transform how they work by identifying issues and improving performance across all areas of the sector.


From component overhaul to aircraft maintenance, turnaround times to workforce planning and the challenges of capacity constraints, we work hand-in-hand with our clients to deliver increased efficiency, productivity, safety and profitability.

MRO providers are under growing pressure to deliver assets back into service with faster turnaround times, maintain airworthiness standards and improve profitability despite resource constraints.

Customer service level expectations?

Increasing demand?

Capacity constraints?

Turnaround time pressures?

Staffing and skills challenges?

Complex supply chain dependencies?

Quality and compliance requirements?

Rising operating costs?

Asset and fleet management challenges?

Major investment programmes?

Talk to us about how we can help.

The MRO challenge

The MRO sector faces unprecedented challenges. Following industry disruption and increased demand, operators must now balance capacity growth with operational efficiency whilst managing increasing cost pressures and customer expectations.

Limited new aircraft availability from manufacturers means the current fleet needs to stay in the air longer, making MRO services more critical than ever. This increased demand is stretching capacity across the sector, with operators facing longer backlogs and pressure to maintain aging fleets.

Labour and skills shortages mean every technician and engineer plays a critical role, making process optimisation, standardisation and effective workforce planning essential. Meanwhile, supply chain complexity and component lead times continue to impact turnaround performance.

Customers and airlines demand shorter turnaround times and higher reliability standards, putting pressure on operators to improve productivity and on-time delivery, all whilst maintaining the highest quality and safety standards and meeting stringent regulatory requirements.

Develop Consulting partners with MRO operators to streamline operations, improve turnaround performance, enhance capacity utilisation and quality, and drive profitability whilst delivering sustainable improvements across the entire operation and supply chain.

Working alongside you to help your business Go further.

We understand change can be difficult and it’s not always clear where to start or what to prioritise.

Develop Consulting works hands-on with your team to identify and make the changes needed to stretch your resources further, put robust planning in place and be able to quickly action improvement for real, tangible and sustainable change.

Our delivery

With much of our team having first-hand experience of Toyota motor manufacturing in the UK and Japan, our preferred delivery model is based on the Japanese Lean methodology, which we have adapted over many years to help MRO providers in Aerospace and Rail set up processes and train people to be more productive, effective and efficient.

In the MRO sector, this approach enhances asset and fleet planning accuracy, coordinates activities in the hangar and supply chain to reduce rework, and improves on-time delivery across line, base and component maintenance.

Develop Consulting will work with your team to transfer our knowledge, ensuring improvements are sustainable and your organisation builds long-term capability within your processes and people.

Projects we have supported

  • Component MRO Turnaround Improvement – Reduced average turnaround times whilst increasing capacity and improving process reliability
  • MRO Process Standardisation – Developed standardised processes across multiple sites, reducing variation and improving performance consistency
  • Capacity and Demand Planning – Optimised workforce planning and resource allocation to match fluctuating demand patterns
  • Warehouse and Logistics Optimisation – Streamlined material flow, reduced component search times and improved kitting processes
  • Quality System Improvement – Standardised inspection processes, reduced defect rates and improved first-time-right performance
  • Layout and Flow Redesign – Optimised facility layouts to increase capacity and reduce waste travel, improving flow and productivity
  • Major Investment Programme Support – From requirements scoping through to implementation, ensuring new facilities and systems are designed for optimal performance
  • Training and Capability Building – Delivered Lean and continuous improvement training to build internal expertise and embed sustainable change

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Let us help your business Go further.