Abstract:
This study aims to enhance the procurement process of an aircraft maintenance company experiencing delays in material acquisition by implementing lean concepts to reduce waste and increase efficiency. The researcher conducts a root cause analysis of the delay problem, identifying raw material shortages as the primary contributing factor. The current purchasing process is scrutinized, with non-value-added activities and waste identified using the eight types of waste principles. Raw materials are categorized using ABC analysis. Subsequently, the researcher designs an optimized purchasing process utilizing ECRS (Eliminate, Combine, Rearrange, Simplify) principles and the Blanket Purchase Order system. This approach aims to reduce purchasing frequency and raw material lead time while selecting high-potential suppliers to ensure timely delivery of quality materials. Results indicate that the newly designed procurement process significantly reduces processing time by 82.82%, from 1,688 hours to 290 hours, and streamlines the number of steps from 18 to 6. Consequently, the company experiences faster raw material receipt and a reduction in material shortages. The average waiting time for purchase orders decreases to 9 days, which is projected to contribute to a reduction in the overall average Turnaround Time (TAT) for maintenance operations. This research demonstrates the efficacy of applying lean concepts to improve the purchasing process, both in terms of enhancing efficiency and fostering organizational sustainability across all dimensions. The findings can serve as a framework for developing robust purchasing processes, equipping organizations with the potential and readiness to address highly competitive business challenges sustainably.