Critical Studies on Cycle Time Reduction Using Lean Tools of Aerospace Components

Abstract

Aerospace manufacturing has high quality and regulatory requirements, and product manufacturing requires maximum accuracy and smoothness. This work highlights how common issues like process waste can be effectively dealt with through main lean tools, such as VSM, Kanban, and 5S. a number of case studies, this research established the initial level of waste with an average cycle time of 12 hours per unit and a defect rate of 8%. Despite this limitation, the study passed targeted lean intervention with flying colours, improving cycle time to 8.5 hours from a previous 12.3 hours (an improvement of 29%), and the defect rate was improved by 44% to 4.5% from its last 8%. Self-organized through VSM to understand and remove non-value-added processes; through observation, communicated and resolved bottlenecks; implemented Kanban to optimize and reduce WIP. The practice of 5S improved the workplace order; particular time saved while searching for items was reduced by about forty%. These results show how these lean tools complement each other if implemented in synergy, creating an environment that improves operational effectiveness and is driven by constant development. Reflectively, the papers offer practical recommendations for practitioners to use in the application of lean strategies for the enhancement of Aerospace manufacturing systems sustainably.