Objectives To identify and propose improvements on aircraft maintenance process focusing on solid waste generation reduction. To establish the integration of Six Sigma, Lean Manufacturing and Cleaner Production to adress the root causes priorization. Ensure the criticality reduction on environmental aspects.
Opportunities Opportunities of environmental impacts mitigation on maintenance include oils, contaminated parts, metals, paint sludge and other s.
Opportunities Market aviation has demonstrated in recent years a exponential growth above 4,4%. Every process or equipment has a normal curve of deterioration increasing waste generation in long term. Maintenance wastes has a important participation in the total cost and environmental impacts from those companies.
Methodology Applied Six Sigma aims by means of tools quality, reduce variations in the process and thus minimize the generation of flaws and defects. The lean manufacturing focus on the removal of seven most common types of losses in the process that generate costs to the company. The unification of these methods to cleaner production was employed to minimize the generation of waste at source.
Methodology Applied Six Sigma Six Sigma focus on process variation reduction. Stage Six Sigma Tools Potencial Results Definition Measure Analysis Improvement Control Voice of the customer, pareto and trend charts. Pareto, flow mapping, fishbone, control chart and brainstorming. Control Chart, DOE, priorization tool. 5W 2H, KAIZEN events. Control Chart, Pareto, Trend charts. Prioritization of waste disposal for analysis. Waste identification / processes with the greatest environmental impact for prioritization Identification of root causes of major disposals processes. Implement the improvements identified in the analysis phase in order to reduce waste generation. Monitoring and maintaining the new level of waste generation in the process.
Methodology Applied Lean Manufacturing Lean focus on seven wastes elimination. Excess inventory Wastes Produce above needs Unnecessary transport of people and materials Unnecessary waiting of people and materials Unnecessary movement of people Unnecessary processing Defects /rework Integration with cleaner production Reduction of waste generation by expired products. Minimizing the generation of waste at source. Reduction of waste generation by winning products. Minimizing the use of materials. Reduced consumption of electricity /fuel and others energy powers. Reducing the emission of pollutants. Minimizing the generation of waste at source. Minimizing the risk of waste generation by maturity or incorrect disposal of materials. Reduction in the consumption of fuel and energy. Minimization of waste generation. Reduced consumption of electricity / fuel and other energy sources. Minimizing the generation and disposal of waste due to poor product quality. Reducing consumption of raw materials. Eliminating the generation of waste at source
Methodology Applied The project was based on the folowing steps and it was developed with a functional team. The lean and six sigma methodologies were adopted to identify opportunities to mitigate the generation of waste at source, within the model implementation of cleaner production.
Scope Airline Brazilian company with about 120 aircrafts (Boeing 737-700/800). Aircrafts corrective and preventive maintenance process. Waste treatment and disposal are performed according to standard ABNT NBR 10.004. Scope include solid waste on aircraft maintenance process and not include other s.
Process Mapping By the use o process mapping was possible to visualize the main process opportunities.
Brainstorming The brainstorming helps team to identify the opportunities of environmental mitigation. INPUTS IPE, Clean cloths, chemicals. Oil / Fluid, blankets absorbent. Metallic replacement parts or not. Rubbers and hoses. Cardboard, paper, taper. Sandpaper, fiberglass. Batteries, electronics (lamps, cables). OUTPUTS Contaminated IPE, contaminated rags. Remains of products. Chemical, oil, fluids and contaminated cans. Blankets contaminated absorbent. Metallic and non-metallic parts for disposal. Rubber hoses and disposal. Recyclable paper, cardboard, plastic, metal. Not recyclable: tape Sandpaper (sanding disc) used, fiberglass. Rubbers and hoses. Batteries for disposal. Electronics (lamps, electric cables).
Root Cause Priorization It was established a priorization tool considering the impact of the waste on Lean, Six Sigma and level of cleaner production.
Root Cause Priorization Principles root causes identified on priorization. Waste Six Sigma Level Lean Manufacturin Cleaner Prod. Level Plastic packaging. 4 3 3 36 Contaminated IPE. 4 3 3 36 Sandpaper (sanding disc) used. 4 3 3 36 Remains of products. chemical, oil, fluids and contaminated cans. Score 4 3 3 36 Paint sludge 3 3 3 27 Ink cartridges for disposal. 4 2 3 24 Contaminated rags. 4 2 3 24 Paper / cardboard. 4 2 3 24 Metallic and non-metallic parts. 2 4 3 24 Electronics (lamps, electric cables. 2 3 3 18
Action Plan It was identified actions focused on environmental aspects reduction as: Procedures changes; Equipments changes; Change in inventory management and consignment shopping; KANBAN Implementation; New area for preparation of solutions
Results With the actions proposed implemented, the environment impact will reduce until 40%.