The aircraft modification sector of the aerospace industry involves the design, build, test, and certification of complex, safety-critical systems for existing aircraft. The high product diversity and low-volume high-value production of this sector results in many unique process challenges. Small-to-medium sized aircraft modification enterprises have adopted product lifecycle management (PLM) methodologies to manage these complex product development processes.

This thesis studies the current-state processes of a typical aircraft modification case study company in Canada, using the research methodology of process mapping. The current-state processes are captured in process maps, which are then assessed to find areas of opportunity for process improvement. The current-state processes are mapped at three different levels of detail: a Tier 1 Phase level, a Tier 2 Milestone level, and a Tier 3 Activity level.

Results of the Tier 1 Phase level analysis illustrate some of the challenges related to simultaneously using multiple PLM methodologies across the product development lifecycle. This finding also affects process communication at the Tier 2 Milestone and Tier 3 Activity levels. Tier 2 Milestone level findings also demonstrate the impact of product diversity on milestone traceability. Tier 3 Activity level findings include the level of detail for effective Tier 3 process mapping, the importance of workflow traceability through documentation, and the challenges of change management.