The modernization of aviation maintenance facilities with LEAN process management tools can lead to the elimination of inefficiencies, simplified operations, and better turnaround times. FL Technics used tools such as structured A3 problem-solving, coordinated communication, and team-based workflow organization to transform the daily processes. The same methodology will be applied at their new facility in Punta Cana, the Dominican Republic.
Companies across industries aiming to stay competitive are turning to LEAN process management to reduce inefficiencies, boost productivity, and build customer trust. The aviation MRO sector, however, faces unique challenges. Base maintenance operations are complex, highly regulated, and traditionally slow to adopt change. As airlines are looking for faster turnaround times (TaT) without compromising service quality, LEAN has become invaluable in process planning, engaging staff, and eliminating repetitive or redundant tasks.
FL Technics, a global aircraft maintenance, repair, and overhaul (MRO) provider, has introduced LEAN principles across its heavy maintenance facilities. This has led to streamlined workflows and improved turnaround times. The company plans to apply the same methodology at its new base in Punta Cana, the Dominican Republic.
In 2013, when Žilvinas Lapinskas took over as CEO of FL Technics, a subsidiary of Avia Solutions Group, the world’s largest ACMI provider, the company faced slow and outdated processes. Determined to modernize its operations, Lapinskas introduced LEAN in 2014, a move that initially faced skepticism in an industry known for its conservatism. The first tangible results appeared after three years, and by the fifth year, FL Technics was already seeing significant operational improvements.
“Implementing LEAN was not easy, especially in aviation, where change often meets resistance,” Lapinskas says. “But by involving our employees and proving the benefits step by step, we transformed our hangars into highly effective operations. Today, LEAN not only improves our service quality and turnaround times but has also earned the trust of leading airlines worldwide. The same approach has already proven successful in our facility in Indonesia, and as we expand to Punta Cana, we bring this philosophy to the Americas.”
From theory to practice
Inside FL Technics, the impact of LEAN is visible in every stage of the workflow. Each morning starts with short stand-up meetings. The teams set priorities, name the challenges, as well as the progress already made. The critical information later cascades all the way up to the CEO level.
Problems are addressed using the A3 methodology, based on the plan–do–check–act cycle. This allows engineers and managers to quickly determine issues, solutions, and implement improvements to make their everyday work easier and more effective.
“We’ve redesigned our hangar’s workflow to make operations more flexible and efficient,” the CEO adds. “By rotating staff according to customer needs and task complexity, and guiding experienced managers, we can allocate people more effectively across projects. This allows us to complete maintenance faster, directly benefiting our airline customers.”
Supply chain management has also been improved with new digital tools that help keep inventory levels just right, making sure the necessary parts are always on hand during maintenance without the need for costly overstocking.
FL Technics has also invested in technology to enhance the accuracy and speed. Tools such as dentCHECK technology, integrated into base maintenance operations, improve inspection efficiency. This handheld, wireless 3D scanner with built-in augmented reality (AR) capabilities provides immediate, actionable measurements of critical airframe damage. It enhances consistency by up to 18 times, accuracy by 20 times, and efficiency with time savings of up to 90%, while reducing human subjectivity in assessments.
Base maintenance teams are now testing helium-based leak detection tools that use helium as a tracer gas. Thanks to its tiny molecules and minimal presence in the atmosphere, helium enables highly accurate leak detection. The method is both faster and more precise than traditional detection techniques.
While the gradual robotization of repetitive tasks — whether in training, procurement, or administrative functions — frees specialists to focus on higher-value work. The company’s teams also benchmark themselves against peers by visiting competing MRO providers and learning from industries further along the LEAN journey.
