Sector: Airline
3rd Party Engineering Maintenance
Scope:
Reduce C Check turnaround for cargo operator
Application:
Based on the methodology LMR devised to reduce A Check turnarounds, LMR applied the same principles to the C Check input for a major international cargo carrier. As with most Lean engagements, a diagnostic to fully understand the constraints was needed before applying the principles of Lean. However, after observing one check, the constraints were identified as being in the following areas:
* Material support
* Task planning and NRC recovery
* Status control of check process
A striking feature of C Check delays was caused by parts availability. An average delay of 17% to the check time was caused by poor material supply. This could be apportioned to poor material stock holdings, lack of appropriate consumables to hand, and a poor hit rate on First Pick Capability from hangar stores.
By applying the ‘Line Back’ principle – following concerns that technicians have when performing the job – LMR was able to confirm that 30% of the delay in production activities was due to peripheral services not responding to check queries as quickly or as effectively as they could. This led to a full review of how services respond to production requirements and an organisational change to functions in order to provide swifter, more accurate responses to technical queries.
This led to the introduction of a basic andon feature to reverse traditional thinking in providing service to production, and driving an escalation process for rapid response to production issues.
Among other tools, LMR introduced a high level work sequence board to control all aspects of the maintenance flow. By plotting the critical path and holding structured status meetings throughout, the maintenance team were able to respond to bottlenecks as they occurred, re-allocate manpower as required, and most importantly, deliver a timely check.
By addressing the material supply issues with the Just In Time Principles, the NRC recovery using andon, and the check status and planning with the work sequence board, our client was able to consistently deliver on time.
Results:
Aircraft check times saw a 45% percent reduction in throughput time with no adverse affect on quality, no addition in manpower, or, most importantly, no adverse affect on safety.
ROI on LMR resource 19:1