Implementing Lean Flow in Customized Aviation Part 145 Repair Station

[gard2372]

Could anyone recommend how to implement Lean in an aviation Part 145 repair station (AS9100 Certified). Although we have an MRO in another hangar, we do completions work on new aircraft per customer options. In essence we are a customizing shop for aircraft ie; DVD players, Custom TV monitors, lighting, interiors etc...

We would like to bring in a lean consultant with aviation experience in a facility who customized aircraft. In lean it seems very tricky when each aircraft can be different = high variability and lean usually works best for repeat processes and low or no variability between products.

Our base aircraft is the same, but each customer requests different options. This poses a conundrum in how we can optimize flow and layout in our cramped facility while trying to incorporate lean into the production flow.

Any ideas or consultant recommendations?

[Jennifer Kirley]

I didn't find anything specific to the business of aircraft repair, so I decided to look through the generic "job shop" concept. I found this site to give you a start. Yoiu would need to apply the concepts to meet your needs.

Anyone else have ideas?

[GeorgeStg]

I need some help with finding downloadable courses for FAR 145 training requirements. In my research the courses I found were expensive and my Manager requested more research for cheaoer or free downloads.
Can anybody please help me?
Thanks
George

[wmarhel]

Check out Lean.org. Under their "Community" -------> "Archives" ------>"Articles" you should find something articles. You'll need to register, but it is free and easy.

You'll find articles such as:

Transforming Tinker: Aging aircraft need more maintenance so Tinker Air Force Base in Oklahoma is trying to free capacity by changing how it performs heavy overhauls on B-52s, B-1s, E-3s and KC-135s. This story in AviationWeek (Dec 11, 2007) surveys the elements of Tinker's hybrid operating system that combines lean principles with the Theory of Constraints and six sigma. The composite system seems to be working. Productivity is up as the workforce holds steady at about 2,200, while flow days and work-in-process are down.


War on Waste: Maintenance Boeing managers describe the application of lean principles in maintenance and repair facilities for Apache helicopters and KC-135 aircraft. Moving lines, standardized work, and visual reporting of production status are among the applications, according to Flight International.

Also, check out the Lean Advancement Initiative at MIT that has a focus on Aerospace.

I hope it helps........

Wayne