Improving Production Efficiency of NC-212 Aircraft Outer Wing Assembly Using Value Stream Mapping and Kaizen Approach
DOI:
https://doi.org/10.12928/si.v24i2.606Keywords:
Aerospace manufacturing, Kaizen, Manpower balancing, Value stream mapping, Wing subassemblyAbstract
Manual aircraft wing assembly is characterized by long lead times, process variability, and waste that reduce production efficiency. This study aims to improve the NC-212 Outer Wing Left-Hand (LH) assembly process by applying lean manufacturing through Value Stream Mapping (VSM), root-cause analysis, and Kaizen-based improvements. Primary data were collected through direct observations, time studies, and interviews across 12 assembly stations. The current-state analysis identified waiting due to pending parts, unnecessary transportation, defects, and manpower imbalance as the dominant sources of waste. Based on Five-Whys and 5W+1H analyses, improvement strategies and takt-time-based workforce allocation were developed to optimize production flow. The proposed future state reduced assembly lead time from 75 to 59 working days (21.3%) and increased average labor utilization to 96.16% through workload balancing and reduced idle time. The main contribution of this study is the application of VSM-based lean improvement integrated with takt-time-based manpower scheduling for a high-mix, low-volume aerospace assembly environment. The proposed framework provides practical guidance for improving workflow synchronization and supporting continuous improvement in aircraft manufacturing systems.
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