Improving workflow of aircraft maintenance for reduce lead-time on nine-passenger aircraft

Aircraft maintenance is an important factor in aviation safety. In carrying out aircraft maintenance, sometimes there is waste in maintenance. This article conducts a case study on a leading maintenance, repair, and overhaul (MRO) in Indonesia, which has a standard maintenance time of 90 hours for periodic inspections every 200-hours of flights for nine-passenger aircraft. In fact, the actual time spent on the workflow was 120 hours. MRO costs are accounting for an average of 14 percent of total expenditure. Therefore, the maintenance period time must meet the predetermined time target to maintain productivity. This study aims to identify waste that occurs using the value stream mapping (VSM) method and determine the criticality level of waste presented in the calculation of risk priority figures using failure mode effect analysis (FMEA), using tools to minimize lead time maintenance services. To reduce lead time in the maintenance process requires the preparation stage for general and special tools, equipment, consumables, and training manuals, as well as additional personnel, there was an increase in the decrease in maintenance time from 120 hours to 103 hours (14.16%). Using lean methods with proposed design improvements to minimize the possibility of waste.