Analisis Waste Manhours pada Proses Perawatan C-Check Pesawat Airbus 330 dengan Metode Value Stream Mapping (VSM)

Abstract

The MRO (Maintenance, Repair, and Overhaul) industry in Indonesia still faces challenges in efficiency, productivity, and global competitiveness, especially against international companies with more advanced technology. PT XYZ, as one of the largest MROs, continues to innovate and optimize aircraft maintenance processes to reduce manhours deviation and achieve Turn Around Time (TAT) targets in line with customer commitments. Uncontrolled increases in manhours lead to higher manhours cost and lower profitability. Form Analysis Profitability Maintenance (FAPM) is used to plan maintenance project profits, where manhours cost is the largest fixed cost. Of 36 C-Check Airbus A330 maintenances conducted between 2022–2024, only nine achieved the FAPM target. This study applies Value Stream Mapping (VSM) to analyze process flow and identify non value added activities. The results show the largest deviation occurred during the inspection phase, particularly in request for material (347.4 manhours) and request for tools and equipment (295.025 manhours), categorized as waste of waiting. Through Root Cause Analysis (RCA) and the 5 Why method, the main causes were data input errors, limited safety stock, suboptimal warehouse layout, and few vendors. Solutions using the 5W+1H approach are expected to reduce deviations, lower costs, and enhance company profitability.