Abstract & Overview
As aviation Maintenance, Repair, and Overhaul (MRO) operations become increasingly complex, Lean Manufacturing offers strategic benefits in improving efficiency and sustaining performance. However, its adaptation in service-oriented MRO settings, particularly in developing countries, remains insufficiently studied. This research investigates lean implementation across three Philippine aviation contexts: a commercial MRO (Lufthansa Technik Philippines), a general aviation center (Omni Aviation), and an academic training facility (Philippine State College of Aeronautics, PhilSCA). Using a mixed-methods case study design, data were collected from 30 semi-structured interviews, direct observations, and operational metrics, including turnaround time (TAT), rework frequency, and technician productivity. Findings indicate that lean tools, such as 5S, Kaizen, and Value Stream Mapping, improve workflow efficiency and reduce errors when adapted to institutional conditions. At PhilSCA, lean functions as a pedagogical framework, aligning instruction with industry needs. The study presents an integrated analytical model that combines the Human Factors Analysis and Classification System (HFACS) with the Maintenance Process Cycle to examine both technical and human factors. While grounded in the Philippine MRO sector, the findings offer relevant insights for similar settings in emerging economies, emphasizing the importance of leadership, contextual adaptation, and the need for training reform to sustain lean transformation.