Non-conformity Mitigation Strategies in Composite Materials: A MASP-PDCA Approach for Sustainable Production in the Aerospace Industry

The manufacturing of composite structures is an essential pillar of the aerospace industry due to the excellent strength-to-weight ratio and outstanding structural performance of these materials. However, because it involves highly complex processes that are extremely sensitive to operational variables, this sector faces constant challenges with structural failures and significant production losses.To overcome these obstacles, this study presents a practical, integrated continuous improvement proposal that combines the PDCA cycle with the Method of Problem Analysis and Solving (MASP), using statistical analyses applied directly on the shop floor. The major differentiator of this work is not merely the diagnosis based on six fundamental dimensions materials, process parameters, equipment, human factors, environment, and operational procedures but rather the methodological articulation of well-established tools, such as the Ishikawa diagram and Process FMEA, integrated within the planning stage of the PDCA cycle. This innovative integration rests on three fundamental practical pillars: the functional fusion of tools that are usually applied in isolation; the quantitative validation of results by product family, comparing indicators before and after the actions taken; and the assurance of aerospace normative traceability, directly linking each corrective action to a Standard Operating Procedure (SOP). To test the model, a practical case study was conducted on a real aeronautical component manufacturing line. Data analysis revealed that only three types of problems stood out — geometric deviations, delamination, and negative deformations and that these issues accounted for approximately 72% of all production losses on the line. In addition, human factors and fluctuations in the material's curing parameters were identified as the crucial determinants behind the occurrence of these failures. Ultimately, the study demonstrates that combining real production data with continuous improvement methodologies is the path to success for reducing waste, saving financial resources, and supporting far more sustainable manufacturing practices.