Optimizing Aeronautical Operations Efficiency with Time and Motion Study

PMI > Blog draft > Aerospace > Optimizing Aeronautical Operations Efficiency with Time and Motion Study

Introduction

In the dynamic world of aviation, every second is counted on the ground. Whether it is the smooth offloading of cargo or the precise coordination of the pre-takeoff checks, ground handling is key to the smooth experience of passengers and the efficient turnaround of planes. An industry leader in aeronautical services identified this critical fact and sought to enhance the efficiency of their ground handling operations after landing and before takeoff. To achieve this, they collaborated with Production Modeling India (PMI) to perform a Time and Motion Study on key operational areas including the Apron Area and Baggage Breakup Area.

Client Background and Objectives

The client has charge of various operations on the ground that occur between an aircraft's landing and the following takeoff. These include management of aircraft at the apron, arranging the transfer of baggage and help passengers in boarding with ease. These operations were inefficient and thus the client sought to identify the shortcoming and create best practices and standard procedures to implement and maintain.

Major study goals were:
• Carrying out a Time & Motion Study on the areas of identification.
• Identifying:
    • What can be done under ideal circumstances.
    • What can be done realistically on a regular basis.
    • What is the existing achievement.
• Finding controllable and non-controllable variables affecting performance.
• Including practical recommendations to minimize delay, optimize manpower utilization, and maintain improvement.

Challenges Faced

Although working in a high-efficiency setting, the client was suffering from recurring apron and baggage handling delays. These delays were affecting not just turnaround time but passenger experience as well. Key issues were:

  • Routine delays of operations throughout the apron and baggage breakup areas.
  • Absence of standardized work patterns causing inconsistency in performance.
  • Challenges in maintaining operational improvements due to insufficient process visibility.
  • Manpower usage inconsistency during peak and off-peak hours.
  • Calculate the buffer capacity required between zones to facilitate smooth operations.

The client sought a structured analysis that would bring clarity, consistency, and control to these mission-critical operations.

Optimizing Aeronautical Operations Efficiency with Time and Motion Study

Download Case Study PDF

PMI’s Structured 3-Stage Approach

PMI approached the problem with a comprehensive 3-phase methodology:

Data Collection

The PMI team, consisting of one project manager and three engineers, began by visiting the client site. They collaborated closely with the client’s cross-functional team (CFT) to understand operational goals and define the scope of the study. The team made on-site observations over several days, taking more than 70 data points per day in various time slots to cover both peak and off-peak hours. Ongoing interactions with ground staff allowed contextualization of the data and accurate information.

Estimation & Data Analysis

Through the use of work sampling and production studies, PMI conducted an extensive Time & Motion study. The information was framed in the form of Excel-based models to compute work distribution, value-added (VA) versus non-value-added (NVA) operations, and manpower utilization rates. Some of the important learnings were:

• Detection of repetitive NVA operations resulting in hidden losses.
• Inconsistent work distribution and idle time for some members of the crew.
• Overloads during peak hours without a corresponding resource allocation.

Dynamic dashboards were designed to aid decision-making and allow operations and manpower allocation in real-time.

Results and Recommendations

The analysis produced distinct, measurable results:
• Specific losses were determined and classified by source, frequency, and effect.
• Explicit recommendations were presented within operational boundaries, such as:
    • Redefining task sequences in order to reduce waiting time.
    • Rotational assignment of tasks to eliminate fatigue.
    • Improved manpower alignment to balance demand cycles.

Optimizing Aeronautical Operations Efficiency with Time and Motion Study

Download Case Study PDF

Conclusion

This case study shows the extent to which a systematic Time and Motion Study can release considerable gains in operating efficiency, even within high-performance contexts such as aviation. Through the analysis of time losses, manpower rebalancing, and sustainable workflow recommendations, PMI helped the client eliminate delays, increase baggage handling speed, and enhance overall passenger service.

With actionable dashboards and data-driven recommendations, the client is now poised to go even further towards leaner, more efficient ground operations—establishing new standards for the aeronautical sector.

    Download Our Company Brochure