• To identify and propose improvements on aircraft maintenance process focusing on solid waste generation reduction.

• To establish the integration of Six Sigma, Lean Manufacturing and Cleaner Production to adress the root causes priorization.

• Ensure the criticality reduction on environmental aspects.

Objectives

• Opportunities of environmental impacts mitigation on maintenance include oils, contaminated parts, metals, paint sludge and other s.

Opportunities

• Market aviation has demonstrated in recent years a exponential growth above 4,4%.

• Every process or equipment has a normal curve of deterioration increasing waste generation in long term.

• Maintenance wastes has a important participation in the total cost and environmental impacts from those companies.

Opportunities

• Six Sigma aims by means of tools quality, reduce variations in the process and thus minimize the generation of flaws and defects.

• The lean manufacturing focus on the removal of seven most common types of losses in the process that generate costs to the company.

• The unification of these methods to cleaner production was employed to minimize the generation of waste at source.

Methodology Applied

• Six Sigma focus on process variation reduction.

Methodology Applied – Six Sigma

Stage Six Sigma Tools Potencial Results

DefinitionVoice of the customer, pareto and trend charts.

Prioritization of waste disposal for analysis.

MeasurePareto, flow mapping, fishbone, control chart and brainstorming.

Waste identification / processes with the greatest environmental impact for prioritization

Analysis Control Chart, DOE, priorization tool.Identification of root causes of major disposals processes.

Improvement 5W 2H, KAIZEN events.Implement the improvements identified in the analysis phase in order to reduce waste generation.

Control Control Chart, Pareto, Trend charts.Monitoring and maintaining the new level of waste generation in the process.

• Lean focus on seven wastes elimination.

Methodology Applied – Lean Manufacturing

Wastes Integration with cleaner production

Excess inventoryReduction of waste generation by expired products.Minimizing the generation of waste at source.

Produce above needsReduction of waste generation by winning products.Minimizing the use of materials.

Unnecessary transport of people and materials

Reduced consumption of electricity /fuel and others energy powers.Reducing the emission of pollutants. Minimizing the generation of waste at source.

Unnecessary waiting of people and materials

Minimizing the risk of waste generation by maturity or incorrect disposal of materials.

Unnecessary movement of peopleReduction in the consumption of fuel and energy.

Unnecessary processingMinimization of waste generation.Reduced consumption of electricity / fuel and other energy sources.

Defects /reworkMinimizing the generation and disposal of waste due to poor product quality.Reducing consumption of raw materials. Eliminating the generation of waste at source

• The project was based on the folowing steps and it was developed with a functional team.

• The lean and six sigma methodologies were adopted to identify opportunities to mitigate the generation of waste at source, within the model implementation of cleaner production.

Methodology Applied

• Airline Brazilian company with about 120 aircrafts (Boeing 737-700/800).

• Aircrafts corrective and preventive maintenance process.

• Waste treatment and disposal are performed according to standard ABNT NBR 10.004.

• Scope include solid waste on aircraft maintenance process and not include other s.

Scope

• By the use o process mapping was possible to visualize the main process opportunities.

Process Mapping

• Contaminated IPE, contaminated rags. • Remains of products. Chemical, oil, fluids

and contaminated cans. • Blankets contaminated absorbent. • Metallic and non-metallic parts for disposal. • Rubber hoses and disposal. • Recyclable paper, cardboard, plastic, metal. • Not recyclable: tape • Sandpaper (sanding disc) used, fiberglass. • Rubbers and hoses. • Batteries for disposal. • Electronics (lamps, electric cables).

• The brainstorming helps team to identify the opportunities of environmental mitigation.

Brainstorming

INPUTS

• IPE, Clean cloths, chemicals. • Oil / Fluid, blankets absorbent. • Metallic replacement parts or not. • Rubbers and hoses. • Cardboard, paper, taper. • Sandpaper, fiberglass. • Batteries, electronics (lamps, cables).

OUTPUTS

• It was established a priorization tool considering the impact of the waste on Lean, Six Sigma and level of cleaner production.

Root Cause Priorization

• Principles root causes identified on priorization.

Root Cause Priorization

Waste Six Sigma Level

Lean Manufacturin

Cleaner Prod. Level Score

Plastic packaging. 4 3 3 36

Contaminated IPE. 4 3 3 36

Sandpaper (sanding disc) used. 4 3 3 36

Remains of products. chemical, oil, fluids and contaminated cans.

4 3 3 36

Paint sludge 3 3 3 27

Ink cartridges for disposal. 4 2 3 24

Contaminated rags. 4 2 3 24

Paper / cardboard. 4 2 3 24

Metallic and non-metallic parts. 2 4 3 24

Electronics (lamps, electric cables. 2 3 3 18

• It was identified actions focused on environmental aspects reduction as: – Procedures changes;

– Equipments changes;

– Change in inventory management and consignment shopping;

– KANBAN Implementation;

– New area for preparation of solutions

Action Plan

• With the actions proposed implemented, the environment impact will reduce until 40%.

Results