Merging of two workshops

Planning and optimization of the Powershop

Lufthansa Technik is a leading provider of maintenance, repair, overhaul and modification services for civil aircraft - from commercial airliners to VIP and specialty aircraft. The company‘s portfolio ranges from customized maintenance programs and engine services to digital fleet support.

With the goal of leveraging synergy potential in its processes and technologies, Lufthansa Technik planned to merge two workshops for aircraft generators and Integrated Drive Generators (IDGs) in a new building at its site in Hamburg. The company drew upon UNITY‘s expertise for this project. Together, they succeeded in developing a new, flexible production system that significantly improves productivity and throughput times. To this end, target concepts for production, logistics and test areas were developed in collaboration with employees from the plant, engineering and logistics departments. The dimensioning and 3D planning of the areas was created taking into account the desired synergies and various growth scenarios. The estimation of investment costs for new equipment and relocation costs that was based on the planning results provided an important decision-making basis for the management. In addition, UNITY created a pilot plan for implementing the measures and learning new processes. This ensures that the desired changes in the new building are implemented and put into practice by all employees. With the workshop designed by UNITY, Lufthansa Technik can realize its long-term growth targets.

UNITY Project Managers: Felix Falbe, Thorben Kerkenberg

Growth of 30% ensured

650 Products integrated into a common production system

Reduces throughput times by 30% an average

“With the help of UNITY, we were able to develop a viable production system in a short space of time that sensibly integrates two workshops and offers many opportunities to improve performance. Thanks to the existing expertise in MRO processes and the close involvement of the employees, good results were achieved quickly and accepted by the team.“


Dennis Litschke

Production System Project Manager

Lufthansa Technik AG

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Thorben Kerkenberg

Head of Smart Factory & Operational Excellence

Hamburg, Germany
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