The lean thinking application in aircraft maintenance

The Portuguese Air Force has been applying lean thinking in aircraft maintenance since the implementation of the F-16 MLU (Mid-Life-Upgrade) modernization program. The aim of this article is to present the work carried out with the purpose of reducing the immobilisation time due to the aircraft maintenance and the cost reduction associated with the support of weapon systems.
The achieved results prompted the development of the application of lean management to programmed maintenance activities for the F-16, Epsilon TB- 30, C-130 and Alouette III fleets. The benefits achieved have been evident, not only at the decreasing of the process times and in the economy achieved in financial, material and human resources, but also in the management ofstocks and in the organizational culture change which hastaken place since its implementation.
The use of the seven-week rapid improvement event method based on the A3 methodology has been instrumental. Leadership actions, strategic alignment and communication throughout the chain of command, along with the involvement of those who have an active part, are crucial in producing the desired end result.
The interventions confirmed a reduction, between 30% and 60%, in the aircraft immobilization time, leading to an increase in the availability of aircraft and a reduction in the operating costs.

Colonel Pedro Salvada is Aeronautical Engineer in the Portuguese Air Force with 30 years of experience. Master in Mechanical Engineering (IST), has several courses of Aeronautics and Lean Management in Portugal and abroad. Colonel Pedro Salvada is the F-16 Program Manager, since 2007, and an encourager of Lean Maintenance Program in Portuguese Air Force.
Miguel Carneiro is Lieutenant in the Portuguese Air Force, a specialty of Maintenance Technician Air Material, degree and master’s degree in Mechanical Engineering from ISEL (2002) and from the Universidade Nova de Lisboa (2013), respectively. Currently holds the position of Quality Officer in Air Base no.1, Sintra.
António Mourão is PhD in Mechanical Engineering from Universidade Nova de Lisboa (2000). He is an associate professor in the Faculdade de Ciências e Tecnologia (UNL) and coordinator of the MSc in Mechanical Engineering. The scientific and pedagogical interests focus on the theory and design methodologies and tolerancing of mechanical systems.

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Aeronautics, Kaizen, Lean Management, Maintenance