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    Taguchi method-based man-hour optimization for boeing 777 a-check interval
    (İstanbul Ticaret Üniversitesi, 2025) Bilgi, Cahit; Eyüpoğlu, Can; Bülbül, Abdullah
    Aircraft maintenance is critical for safety and operational efficiency. For the Boeing 777, A-checks are conducted every 1000 flight hours (FH), resulting in five checks per aircraft annually, with significant downtime and labor costs. This study proposes a Taguchi method-based manhour optimization model extending the A-check interval to 1500 FH and reducing the number of annual checks while maintaining safety and regulatory compliance. The analysis carried out in this study revealed significant benefits of this interval extension. Annual downtime for the 12-aircraft fleet decreased from 60 to 40 days, allowing 20 additional operational days and generating $1 million in extra revenue. Labor costs were also reduced, with annual man-hours dropping from 1586 to 1153 per aircraft, saving 5196 hours fleet-wide. This optimization translates to $416.000 in labor cost savings annually, with a total financial benefit of $1416 million. Redistributing tasks between A- and L-checks further enhanced efficiency. Tasks such as lubrication and minor inspections were consolidated, and comprehensive cabin cleaning at 1500 FH was supplemented with intermediate cleaning at 500 FH to maintain passenger experience. These adjustments balanced the workload without affecting turnaround time or safety. This optimization demonstrates the potential for significant cost savings and operational improvements in aviation maintenance. Extending the A-check interval increased fleet availability, reduced labor requirements, and ensured compliance with regulatory standards. The findings highlight the importance of strategic maintenance planning and the potential for similar optimizations across other aircraft types and fleets.