Management challenges and opportunities in aircraft maintenance repair and overhaul organisations in Malta : a case study at Lufthansa Technik Malta

Abstract

The main objective of this study is to discover how and why unscheduled maintenance work on an aircraft could be predicted, controlled and managed. In this regard, delivering an airworthy aircraft and on time to the customer is important and failure to meet this requirement will impact on the reputation of the maintenance, repair and overhaul organisation. With this in mind, the research investigated how bay managers and maintenance staff of Lufthansa Technik Malta do manage and control the uncertainty and challenges that non-routine maintenance creates on their projects’ turnaround times.

Supported by the literature review, the study investigated why non-routine work develops and up to what extent Lufthansa Technik Malta can turn the customer’s aircraft around quickly. This depends largely on unscheduled work. The research method used involved both qualitative and quantitative data. The quantitative data is comprised of aircraft historical data that was over the period of two consecutive years. It incorporates information that is related to flight hours, flight cycles, aircraft age, operating environment, defect ratios, discrepancy rates and non-routine task cards that are generated. On the other hand, the qualitative data is composed of 6 semi-structured interviews with the bay managers who shared their daily experiences and challenges in managing their turnaround projects.

From the study it emerged that respective bay managers could no longer plan their TAT of their projects. The latter claimed that these targets are unachievable due to the fact that Lufthansa group restructured its operations from a divisional to a centralised one. This was found to be the main issue contributing to the excessive number of delays that LTM is experiencing. Furthermore, problems with delayed issues are also coming from the OEM. According to the six bay managers these are affecting all aircrafts’ delays. These are associated with the removal of the core structure team from each bay, the rigidity and limitations of the authorisation system, the lack of skilled inspectors, shortages of skilled staff, and the current shift workforce pattern, according to the six bay managers are all affecting aircrafts’ delays. Aircraft maintenance by it is nature is very complex and the research brought about light that unscheduled maintenance is only part of the problem that causes late deliveries. LTM ought to be more efficient and more effective to its operations needs that are all aimed at revising the above mentioned processes and procedures to increase customer value. In this regard, it is hoped that this research will serve as a backdrop for the management to address the key issues that needs to be tackled. Eventually, the implementation of the suggested recommendations will lead to a more efficient and effective operations.