Development of Aircraft Maintenance Procedures Using Lean Tools

The current problem of the maintenance, repair, and overhaul (MRO) organizations is competitiveness in the environment of aircraft maintenance, which is the main task is to improve the quality of the maintenance and reduce aircraft downtime. This study examines how the MRO can improve the procedures of individual aircraft maintenance task cards by implementing Lean tools, in the combination of the Six Sigma methods. The aim is to minimize downtime of the aircraft and analyze the processes to determine the existing problems in this area. Applying the data collected from the experts of the MRO, airlines, and equipment manufacturers, an analysis was made on engine replacement using a modern hydraulic lift engine hoist. The result shows this approach allowed to eliminate unnecessary tasks from the aircraft maintenance manual (AMM) and also reduce turnaround time by more than 4 h. The measurement based on the final results validates the main contributions o MRO organizations through savings in finance and human resources, thereby reducing maintenance costs and satisfying the customer.