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This paper gives a summary of a thesis project conducted at KLM Royal Dutch Airlines Engineering and Maintenance. The research focuses on redesigning maintenance processes to increase the delivery performance of the A-check from a lean perspective. A theoretical framework is formulated based on the combination of lean thinking, six sigma and the theory of constraints. The A-check maintenance processes are analyzed from the gate (on-blocks) back to the gate (off-blocks). The chain of processes is analyzed with regard to the five lean principles. Through this analysis three improvement areas are identified namely buffer reduction, improved position management and reduction of interference between the (re)arranging process and the engine-run process. The processes are redesigned such that a future state is developed with improved customer value through increased delivery performance. Based on a reduction in waste and increased utilization of the primary constraint the delivery performance of the A-check is estimated to increase with 92%. The future state is designed in two phases namely an immediate solution which requires no significant investments and can be implemented right away and an ultimate solution.
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