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Lean for Aircraft Maintenance:
Learning by Doing
Damian Murphy
Royal Aeronautical Society Conference
05th September 2017
Increasing Efficiency & Reducing Cost within the Aircraft
Maintenance Process using New Technology & Innovative Solutions
Damian Murphy
Introduction
The Organisation
• Flagship Airline
• Widebody Fleet
• Airbus A330’s
• A-Check Process
• Process relocated from a sub station
to the base station.
A330 A-Check Process
The Problem
• The A-Check process for the fleet is
inconsistent & unreliable.
• The business cannot rely on the
Maintenance Department to release
the aircraft on time.
The Challenge
• Address the problem in the short
term.
• Streamline the process to create
additional asset availability in the
longer term.
Lean Thinking already established within M&E
2013/2014 - Lean Transformation
Lean
Culture
Embedded
Lean &Innovation
Lean Black Belts in M&E
2012 - Lean DevelopmentLean
Steering Team
Lean Training & Coaching
Multiple Lean Projects
5S Roll Out
2011 - Lean Introduction
LeanGovernance
LeanProjects Register
LeanPilot Teams
Lean Training
• Custom designed in-house Training Programmes
• Lean Methodologies & Tools
• Learning by Doing philosophy
Lean Education
• Identifying the Right Candidates
• Distance Learning with the University of Limerick
• Lean Six Sigma - Black Belt Qualifications
First Lean Project: 5S in the M&E Offices
BEFORE AFTER
2.5
3.0
3.5
4.0
4.5
5.0
Axi
s Ti
tle
5S Score - M&E
5S Score
Target
Early Process Improvement Wins
PAPERWORK: RIGHT-FIRST-TIMEREDUCED ENGINE RUNS
Lean & Innovation: Custom-built Wheel Change Truck
Lean & Innovation: Mobile Workshops
The A-Check: our biggest Lean challenge
The Basics
• The application of the Lean tools and
techniques.
• Academic research demonstrates
that successful Lean implementation
requires numerous other factors to
play a part ………
The Essentials
• Strong leadership
• Creating & maintaining a sense of
urgency
• Senior management buy-in
• A clear vision with goals
• An iterative change process
• Real engagement from stakeholders
The Research
Three themes emerge …
1. Creating the right conditions for Lean.
2. Learning by Doing
3. Growing a Culture for Change
From these themes the researcher created a preliminary Model for Lean
implementation in an aeronautical A-Check.
A-CHECK ISSUES BOARD
PRE CHECK MEETINGS
POST CHECK MEETINGS
PERFORMANCE
GRAPHS
ITERATIVE CHANGE
PROCESS
A-CHECK
VISIBILITY BOARD
REPLACE EMAIL WITH
FACE-TO-FACE
COMMUNICATION
Create an environment for Initiating, Leading,
Achieving & Sustaining Change
A-CHECK VALUE
STREAM CONCEPT
STRONG LEADERSHIP
PRESENCE & SUPPORT
ALL STAKEHOLDERS TO
ATTEND POST CHECK
MEETINGS
HIGH LEVEL
A-CHECK SPONSOR
INITIAL A-CHECK VISION
& GOALS
CREATE A NEW VISION
FOR A-CHECK BEST
PRACTICE
LEAN IMPLEMENTATION MODEL:
AERONAUTICAL A-CHECK
CONDITIONS
FOR LEAN
LEARNING
BY DOING
A CULTURE
FOR CHANGE
CREATE A SENSE OF
URGENCY FOR THE
A-CHECK CREW
INTEGRATE
A-CHECK CREW &
SUPPORT TEAMS
(Final Version)
LEAN TRAINING
& SKILLS
This paper focuses on the ‘Learning by Doing’ theme
which sits at the heart of the Lean implementation
model..
Research Methodology
• Insider Action Research
• This facilitated the application of an
iterative change process.
Our Iterative Change Process
• Planning
• Action
• Observing
• Evaluating
Application of an Iterative Change Process
Established Processes
• Big and complex processes
accumulate waste over time.
• This waste gets weaved into the very
fabric of the process.
• Something has to change.
Controlled Incremental Change
• Addressing hundreds of small issues.
• Taking the ‘noise’ out of the process.
• Building trust.
• Real engagement.
• Collaborative solutions.
• Experimentation.
• Safety is King.
• Learning by Doing.
Fit-for-Purpose Tools & Fixtures
1
Resource Allocation & Area Organisation
4
5
6
7
8
9
1 10
2 11
3 12
A330 A-Check: Set-Up Plan
Open Main Gear Doors
Position Horse Boxes X 3
Position Five Step Stand X 1 Position Lights on Wheel Stands X 4
Insert Nose Gear Door Locks X 2
Position Airline PIGs with Reels X 2
Position Wheel Well Stands X 2for Landing Gear section
Main Gear
Nose Gear
Open Nose Gear Doors
Position Five Step Stand X 1
Position Steps for Wheel Well Stands X 2
Insert Main Gear Door Locks X 2
Insert RAT Lock using an MWP
2
5 6
5 6
8
9
12
910
8
8
Under-Wing Mobile Computer Stations
Taking the Noise out of the Process!
Issues captured in real time during
the A-Checks.
Each solution given an owner and a
target closure date.
Post A-Check Reviews.
Reviews attended by all
stakeholders including the M&E
Director.
Solutions agreed by consensus.
200 issues resolved over 12 months!
Bench Marking in search of Best Practice
Vending Machines for Maintenance Consumables
The Benefits
• 24/7 instant access at the
aircraft
• Zero stock-outs
• 2,500 stock items
• Pay at point-of use
• 40% Cost Reduction
Our Results: achieving Best-in-Class Turnaround Times
2
4
34.0 Hrs
25.9 Hrs
23.0 Hrs
22.3 Hrs 22.0 Hrs
20.7 Hrs
14.6 Hrs
14.0 Hrs
13.7 Hrs
12.7 Hrs
12.1 Hrs
Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14
Lean Implementation
Project Plan & Time Line
A330 A-Check
Turnaround Time
A330 A-Check
Vision - Charter - Team Assembly
VisibilityBoard - Issues Board - KPI's
Pre Check Meeting - Post Check Meeting
Training Versatility Matrix
A-Check Set-Up - AMOS Utilisation
5S - Seats in Service Review
Quality Knowledge Database
Business Class Seats - Check List
Stands Fit-for-Purpose - New Lights
Engine Run on First Shift - Mobile Work Stations
Critical Path Tracker - Material Task Lists
Process for dealing with Surprises
Supervisor Sign-off's on Late Shift
Vending M/C's for Consumables
A330 A-Check Deliverables
Aer Lingus becomes the new benchmark for A330 A-Checks
Learning by Doing: Lean driving Competitiveness
5S Roll OutMultiple
Small Wins
Lean
- D
rivi
ng
Co
mp
etit
iven
ess
Lean Journey in Aer Lingus
Catering & Bond
Initiatives
2015
Raising the Bar
2014
Best Practice
2013
Lean Transformation
2012
Integrated
Operations Centre
Aircraft Turnarounds
Bases & Out Stations
Building a Platform
2011
Thinking Lean
Lean & Innovation
A330 A-Check
Lean Transformation
Training & Coaching
M&E Value Streams
Development Phase
European Bench Marking
M&E Value Streams
Launch Phase
Roster Lifecycle
Communication
First Wave Departures
Dublin BaseUK Bench Marking
Maintenance & Engineering
Aer Lingus Operations
