Innovative Approach in Introducing Lean Manufacturing Tools in Maintenance of Aircraft

Abstract

Lean manufacturing was initially introduced successfully in Japan to enhance the production standard of cars in Toyota Company. These lean principles were initially known as Toyota Production system (TPS)[2]. Lean seeks to eliminate all forms of waste in the manufacturing process—including waste in the maintenance operation [1]. This present study about lean principles if could be introduced in maintenance of aircraft the standard of maintenance process could be significantly improved. Hence study of experimental research was carried out on pre-matured failure of lifed hydraulic components of ten aircrafts. The failure rate of each component was studied in-depth to adopt remedial measures for improving its life and in turn to reduce the period of “Aircraft on Grounds”. Aircraft on ground mean unserviceable aircraft will be on ground and not suitable for flying. In addition, a deep study was made on each component to fix a Time Between Overhaul (TBO) by analyzing the failure trend of each component to determine a common and effective TBO for enhancing the serviceability rate of aircrafts. It also prevents sudden failure of components thus improving the serviceability status. In order to enhance the standard of serviceability a “Root Cause Analysis” was carried out on those defective components to suggest remedial measures to those maintenance personnel to modify the maintenance process and reduce the TBO for effective reduction in time of occurrence of the defects. These suggestive measures were implemented by the users of the ten aircrafts on trial basis. Occurrence of such defects was minimized showing significant improvement in the subsequent maintenance of aircrafts. Further, the remedial measures have a great impact on the development of a high degree of aircraft maintenance. The final results of this research study are prepared and suggested measures are forwarded for implementation to manufactures, overhaul agency and operators.