Aircraft Maintenance – Quality Cost to the Airline

Mahmood Manzoor

Year:    2002
Category:   Quality Tools
Source:   ICQI 2002 – Pakistan 7th International Convention on Quality Improvement, Karachi
Publisher:   PIQC Institute of Quality

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Author’ Introduction:   

Mahmood Manzoor has over Thirty (30) years of aviation experience with Pakistan International Airlines Corporation. He is a Mechanical Engineering from NED University of Engineering & Technology, Karachi. He did his Master of Business Administration from Institute of Business Administration, Karachi. Mr. Mahmood Manzoor is a Certified Quality Professional from NED University of Engineering & Technology/ Pakistan Institute of Quality Control and a Certified Quality Manager for American Society for Quality (ASQ). He has also possessed the Lead Auditor Course Certificate from Moody International, England.

Abstract   

In today’s competitive business environment, companies are forced to adapt more efficient strategies for their survival and development. Quality and continuous improvement have become the main elements in strategic planning for companies desiring to achieve long-term market success.

In a strategic context, quality has undergone a radical evolution, shifting from a largely technical orientation to a cultural phenomenon. Quality tools, the methods and techniques used to solve any quality issue, have also evolved with quality; from the seven basic quality tools, today they include tools to address any quality issue.

As continuous improvement evolved, six-sigma (eliminating defects) and lean (eliminating waste) concepts were adopted to improve business results. These efforts improved overall efficiency and effectiveness of specific processes, but they were very focused and limited in scope. This led to integration of six-sigma and lean as a company-wide strategy at many businesses.

Messier-Dowty is the world leader in the design, manufacture and support of commercial and military aircraft landing gear systems. The company is facing unprecendent ramp-up levels and challenges of stringent market conditions. The company has responded to these challenges with a strategy, ‘The Messier-Dowty Way’, to maintain its position of world leader.

‘The Messier-Dowty Way’ integrates six-sigma and lean for business improvment to achieve a successful balance of cost, quality and delivery performance, The integration of six-sigma and lean defines the ‘Corrective, Improvement and Development (CID) Approach’ for the Messier-Dowty business solutions.

  • ‘Corrective’ approach employs 8-D tools for recovering standard performance.
  • ‘Improvement’ approach employs Kaizen and DMAIC for improving performance.
  • ‘Development’ approach employs the concept of Business Process Reengineering for radical changes.

Messier-Dowty has achived significant cost savings ($$) by applying the quality tools to its portfolio of projects. The application of the quality tools has also resulted in visible improvement in the domains of lead time reduction, supplier quality and delivery, eleminating bottlenecks and product line optimization.

The ‘Messier-Dowty Way’ exhibits a very good example to demonstrate how the application of quality tools can enable a company to meet the challenges of the competitive business environment and maintain its position as a world leader in its market segment.