Optimization of Operational Efficiency in the Production of Composite Aircraft Structures

The aerospace industry faces growing pressure for operational efficiency to keep pace with the high production rates of next-generation programs. This evolution is directly linked to the increasing use of carbon fiber and glass fiber reinforced polymers, both in commercial aircraft where the appeal of improved "fuel efficiency" sets an increasingly demanding market standard and in military aircraft, which require parts with increasingly complex geometries and high structural integrity. In this context, the competitiveness of the aerospace industry depends on extracting maximum performance from increasingly sophisticated machines and equipment, such as autoclaves, CNC machining centers, and ultrasonic testing (UT) systems, since investment in new machinery and technologies tends to be approached cautiously.The objective of this study is to describe a capacity expansion project conducted in partnership between Companies A and C, for civil and military programs. Rather than purchasing new equipment, a low-cost path was chosen, applying Kaizen event methodology and work standardization, implemented and monitored over a six-month period, comparing availability and efficiency indicators before and after each intervention, with measurements collected shift by shift in the sectors involved. The targets were clear and well-defined: a 20% increase in the availability of critical equipment and a 10% efficiency gain in workline setup.The results confirmed the objectives: autoclave cycle time dropped by 17% in the TEP and AU10 programs, and assembly and finishing time at the Composite Machining Center was reduced by 32%. These gains were achieved mostly through the production team's own time dedicated to Kaizen events, without the need for new investment in machinery, creating an alternative that was much cheaper and faster than expanding the plant with new equipment, whose return would take years to pay off.In summary, the study shows that small process changes, well-planned and rigorously measured, can improve the efficiency of existing equipment and increase productivity, ensuring economic reliability and long-term sustainability in the manufacturing of primary composite structures.