Theory of Constraints in Parts Repair

01:22:17Recorded on 15 June 2020

Christian Pohle(Lufthansa, Germany)

Lufthansa Technik AG is the Lufthansa Engineering group that provides maintenance, repair, and overhaul services for aircraft, engines, and components. Christian shows how they used the theory of constraints to identify and address bottlenecks in the parts repair process.


Christian Pohle is Head of Process at Lufthansa Technik. His process mining journey started off with an unusual situation: They had great data. Their ERP system collects very detailed and accurate information about all the steps that happen in the parts repair process. So, they were in an excellent position to use that data for their process mining analysis.

With his background in Lean Six Sigma, Christian could use the lean methodologies of continuous improvement and combine them with process mining. One interesting tool that they used is the Theory of Constraints, which is a technique that focuses on finding the biggest bottleneck and resolving it, then finding the next-biggest bottleneck and resolving it, etc.

Instead of working on individual transformation projects, they used an Agile approach to implement and review the improvements in sprints. This led to an openness and honesty that were appreciated throughout the company. In his remarkable story, Christian brings to life how process mining helps to move discussions “from the belly to the brain” through objectification of gut instinct.

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