Implementation of Lean Manufacturing to Increase Aircraft

William Orbegoso; Luis Cevallos; Edilberto Miguel Avalos Ortecho

doi:10.11159/jffhmt.2025.048

Implementation of Lean Manufacturing to Increase Aircraft

William Orbegoso
, Luis Cevallos
, Edilberto Miguel Avalos Ortecho

Research output: Contribution to journal › Article (Contribution to Journal) › peer-review

Abstract

Aircraft availability is a crucial factor in ensuring the continuity and effectiveness of pilot
training programs. In the aeronautical industry, maintenance complexities and operational variables
CONTACT US
represent challenges to maintaining a constant operational fleet, resulting in economic losses and
operational delays. This study aims to address the problem of low aircraft availability in a civil aviation
training center by implementing Lean Manufacturing tools to increase aircraft availability. The research
demonstrates that by applying techniques such as Total Productive Maintenance (TPM), process
automation, and predictive maintenance, it is possible to increase aircraft availability and reduce
operating costs. A simulation model was developed using Arena software to validate the impact of these
improvements, showing an increase in availability from 60.56% to 83.75%. The results highlight a
significant reduction in maintenance downtime, increasing availability by 12% due to a decrease in
MTTR from 7.278 Hrs/failure to 3.807 Hrs/Failure and an increase in MTBF from 12.7 Hrs. to 60.5 Hrs., as
well as improvements in operational efficiency with an 86.67% improvement in filling out the Aircraft
Technical Log (ATL) and a 73.62% improvement in filing flight plans, which contributes to increasing
profitability from PEN 29,100 to PEN 52,700.

Original language	English
Number of pages	10
Journal	Journal of Fluid Flow, Heat and Mass Transfer
DOIs	https://doi.org/10.11159/jffhmt.2025.048
State	Published - 22 Dec 2025

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure
SDG 12 Responsible Consumption and Production

Access to Document

10.11159/jffhmt.2025.048License: Unspecified

Cite this

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title = "Implementation of Lean Manufacturing to Increase Aircraft",

abstract = "Aircraft availability is a crucial factor in ensuring the continuity and effectiveness of pilot training programs. In the aeronautical industry, maintenance complexities and operational variables CONTACT US represent challenges to maintaining a constant operational fleet, resulting in economic losses and operational delays. This study aims to address the problem of low aircraft availability in a civil aviation training center by implementing Lean Manufacturing tools to increase aircraft availability. The research demonstrates that by applying techniques such as Total Productive Maintenance (TPM), process automation, and predictive maintenance, it is possible to increase aircraft availability and reduce operating costs. A simulation model was developed using Arena software to validate the impact of these improvements, showing an increase in availability from 60.56\% to 83.75\%. The results highlight a significant reduction in maintenance downtime, increasing availability by 12\% due to a decrease in MTTR from 7.278 Hrs/failure to 3.807 Hrs/Failure and an increase in MTBF from 12.7 Hrs. to 60.5 Hrs., as well as improvements in operational efficiency with an 86.67\% improvement in filling out the Aircraft Technical Log (ATL) and a 73.62\% improvement in filing flight plans, which contributes to increasing profitability from PEN 29,100 to PEN 52,700.",

keywords = "Lean manufacturing, aircraft availability, efficiency, total productive maintenance.",

author = "William Orbegoso and Luis Cevallos and \{Avalos Ortecho\}, \{Edilberto Miguel\}",

year = "2025",

month = dec,

day = "22",

doi = "10.11159/jffhmt.2025.048",

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journal = "Journal of Fluid Flow, Heat and Mass Transfer",

issn = "2368-6111",

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TY - JOUR

T1 - Implementation of Lean Manufacturing to Increase Aircraft

AU - Orbegoso, William

AU - Cevallos, Luis

AU - Avalos Ortecho, Edilberto Miguel

PY - 2025/12/22

Y1 - 2025/12/22

N2 - Aircraft availability is a crucial factor in ensuring the continuity and effectiveness of pilot training programs. In the aeronautical industry, maintenance complexities and operational variables CONTACT US represent challenges to maintaining a constant operational fleet, resulting in economic losses and operational delays. This study aims to address the problem of low aircraft availability in a civil aviation training center by implementing Lean Manufacturing tools to increase aircraft availability. The research demonstrates that by applying techniques such as Total Productive Maintenance (TPM), process automation, and predictive maintenance, it is possible to increase aircraft availability and reduce operating costs. A simulation model was developed using Arena software to validate the impact of these improvements, showing an increase in availability from 60.56% to 83.75%. The results highlight a significant reduction in maintenance downtime, increasing availability by 12% due to a decrease in MTTR from 7.278 Hrs/failure to 3.807 Hrs/Failure and an increase in MTBF from 12.7 Hrs. to 60.5 Hrs., as well as improvements in operational efficiency with an 86.67% improvement in filling out the Aircraft Technical Log (ATL) and a 73.62% improvement in filing flight plans, which contributes to increasing profitability from PEN 29,100 to PEN 52,700.

AB - Aircraft availability is a crucial factor in ensuring the continuity and effectiveness of pilot training programs. In the aeronautical industry, maintenance complexities and operational variables CONTACT US represent challenges to maintaining a constant operational fleet, resulting in economic losses and operational delays. This study aims to address the problem of low aircraft availability in a civil aviation training center by implementing Lean Manufacturing tools to increase aircraft availability. The research demonstrates that by applying techniques such as Total Productive Maintenance (TPM), process automation, and predictive maintenance, it is possible to increase aircraft availability and reduce operating costs. A simulation model was developed using Arena software to validate the impact of these improvements, showing an increase in availability from 60.56% to 83.75%. The results highlight a significant reduction in maintenance downtime, increasing availability by 12% due to a decrease in MTTR from 7.278 Hrs/failure to 3.807 Hrs/Failure and an increase in MTBF from 12.7 Hrs. to 60.5 Hrs., as well as improvements in operational efficiency with an 86.67% improvement in filling out the Aircraft Technical Log (ATL) and a 73.62% improvement in filing flight plans, which contributes to increasing profitability from PEN 29,100 to PEN 52,700.

KW - Lean manufacturing, aircraft availability, efficiency, total productive maintenance.

U2 - 10.11159/jffhmt.2025.048

DO - 10.11159/jffhmt.2025.048

M3 - Artículo (Contribución a Revista)

SN - 2368-6111

JO - Journal of Fluid Flow, Heat and Mass Transfer

JF - Journal of Fluid Flow, Heat and Mass Transfer

ER -