First Steps to Lean Success for Team Apache

UK Ministry of Defence, Work has begun on the introduction of a lean pulse-line for depth maintenance for the Apache helicopter at Wattisham Airfield in Suffolk. 
 
This will involve dividing the maintenance work into timed phases and fitting out a work station to complete the tasks for each phase. At the end of each phase the helicopter moves (pulses) to the next work station in the line to complete the next phase. 
 
The lean team have produced an initial design for a pulse-line based on 35 services a year and one based on 60 services a year which will take effect when more Apaches enter service. 
 
A separate working pulse-line has been created for the mechanical components of the rotor head. The rotor-head pulse-line has reduced the time taken for services from around 240 hours to 133 hours. 
 
The lean experience is proving popular with technicians. SERCO engineer Andy Smith has made the most of the opportunity to innovate and develop expertise. He devised a method of replacing faulty bearings in the rotor head at the bench using a hydraulic system, rather than returning them to the manufacturer, a saving in time and cost. 
 
Lt Col Phil Davies, Depth Support Manager, AH IPT, is setting up and running the depth support unit. He said: 
 
“Since Apache is a new airframe there is nothing comparable to this project. This creates challenges but it also means there are no entrenched practices to overcome. We have a blank canvas on which to create something unique.”