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Redesigning An Aircraft Plant with Simulation

Leveraging advanced simulation, we model and redesign our Client's facility from an OEM (Original Equipment Manufacturer) to an MRO (Maintenance, Repair & Operations) aircraft plant.

Approach & Solution



Our Client is an American aerospace manufacturer with global service operations. Their aircraft engines are widely used in both civil and military aviation. Our team was brought in to help the customer’s project leaders validate their design decisions.

The model would help them better visualize their future layout, run what-if scenarios to meet the demands of their future workload.

We utilized simulation software to virtually simulate the customer's entire process. After we completed the design and virtual simulation of the plant layout, we analyzed the minimum resources needed to attain the customer's future repair workload goal. All these analyses were summarized and visualized within charts, tables and one big report.

The simulation delivered was also flexible enough so that the customer would be able to create new scenarios within their process and analyze the results moving forward.


Leveraging Siemens Tecnomatix Plant Simulation software, we built 3D plant simulation model to enable data-driven redesign of the customer’s existing production plant into a maintenance & repair facility for aircraft.

We also executed Work-in-Progress (WIP) analysis and workforce utilization analysis studies to identify operational bottlenecks and identify improvement opportunities.

Finally, we analyzed model data and presented results to validate their plan to optimize plant layout, resource allocation, capacity planning and throughput.


Increased product design & engineering efficiencies

Ensured efficiency & productivity of future aircraft repair facility

Lowered investment risks through early PoC

Optimized manufacturing resources (machines, etc.)

Enhanced visibility and integration of business and factory systems

Enabling Technologies

Digital Twin

Project Team

Engineering USA
Industries eXcellence