From turbulence to efficiency: Optimizing the Airbus A320 pre-redelivery records using DMAIC and lean principles

The aircraft leasing industry is experiencing a growing trend of lease extensions, delaying aircraft redeliveries and raising the prospect of a future surge in transition activity. This development poses risks for lessors, including costly Aircraft on Ground (AOG) events, delayed remarketing opportunities, and disputes over technical records. The pre-redelivery records review (PRR) process is a critical enabler of efficient lease transitions, yet inefficiencies in its execution contribute to delays and additional costs. This study examines whether improvements in the PRR process can be achieved through the application of Lean principles using the DMAIC (Define–Measure–Analyse–Improve–Control) framework. A single case study was conducted within a large global leasing company, focusing on Airbus A320 aircraft. Data collection combined semi-structured interviews with eight subject matter experts and analysis of 342 PRRs completed over an 18-month period. Lean tools, including Value Stream Mapping, Fishbone diagrams and Pareto analysis, were employed to diagnose process inefficiencies and develop targeted improvements. The results demonstrate significant enhancements to the PRR process, including a reduction in average cycle time from 65 to 16 days, a 48% reduction in required records, and an 83% reduction in template complexity. Financial modelling indicates significant cost savings over a two-year period, alongside an estimated reduction in travel-related carbon dioxide emissions associated with the adoption of remote reviews. The study highlights the potential of Lean methodologies to improve operational efficiency in aircraft leasing transitions, offering both economic and sustainability benefits for lessors and the wider air transport industry. • Lean Six Sigma applied to pre-redelivery records reviews in aircraft leasing. • PRR cycle time reduced by 75%, from 65 days to 16 days. • Required PRR records reduced by 48%, streamlining documentation. • Template complexity reduced by 83% through Lean mistake-proofing. • Remote PRRs delivered average cost savings of 46% per review.