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Optimizing Engine Maintenance Processes through Arena Simulation Modeling

Anas A. Shargawi1*, Seraj Y. Abed2, Christina Knopp3

Aviation industries strive to deliver timely, safe, and airworthy aircraft (ACFT) to meet customer needs. ACFT maintenance involves adhering to planned requirements based on policies and standards. This case study examines the routine heavy maintenance processes of a major airliner during its privatization efforts, focusing on low operating costs, operational efficiency, and safe travel for both local and international passengers. Minimizing ACFT maintenance ground time has become crucial for Maintenance Repair and Operations (MRO) facilities to remain competitive in the global market. Therefore, it is essential to reassess existing processes, identify bottlenecks, and seek areas for improvement. A discrete simulation model was developed to study the maintenance processes of General Electric Engines during a heavy maintenance check on the Boeing 747. The model simulated the simultaneous maintenance procedures of all four engines, with each engine following the same set of processes and procedures. The simulation results revealed significant potential opportunities to reduce engine maintenance time by approximately 37%. This reduction in time holds the potential for significant cost savings, particularly considering that the company’s standard hourly ground cost is approximately $2,777.78.