Improving Lead Times in Aircraft Wiring Installation Using Lean and Six Sigma Methodologies

Lean and Six Sigma (LSS) are well-known techniques of enhancement efficiency and quality in manufacturing, but LSS implementation at the level of subsystem in aerospace production has been limited. The process of wiring installation is intensive and error-prone and has an immense effect on the aircraft production schedule. Lead time and rework are the root cause of schedule inefficiencies on the production line. In this Praxis, the Lean and Six Sigma methodologies were implemented using the DMAIC framework to measure performance in wiring installation at an aerospace company and to improve the conditions. This research was conducted using one installation plan with the Loose Connector defects being the most prevalent and influential source of inefficiency. Lean and Six Sigma tools such as Pareto analysis, control charts, and root cause analysis were used to determine areas of improvement opportunities, and the implementation of the changes was proven using statistical testing. This research substantiated the fact that the improvement of lead times in wiring installation and the rework reduction, while maintaining airplane production output, are possible using Lean and Six Sigma. This research adds to the academic knowledge base by showing that process improvement in aerospace manufacturing should be addressed at the subsystem level. Although this research focused on Loose Connectors, the method can be extended to other types of wiring installation defects and transferred to other industries where wiring complexity and rework are also common problems, such as the automotive and semiconductor sectors.

Author

• McLemore, Brittany

Language

• en

Keyword

• manufacturing
• LSS
• engineering management

Date created

• 2026

Type of Work

• Dissertation

License

• All rights reserved

Rights statement

• In Copyright

GW Unit

• Engineering Management

Degree

• D.Engr.

Advisor

• Clift, Jennifer

Committee Member(s)

• Blackford, Joseph
• Bierce, Jonathan

Persistent URL

•  https://scholarspace.library.gwu.edu/etd/xg94hq522