Implementation of Lean Manufacturing to Increase Aircraft

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
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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.