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This paper focus on a development and implementation of a systematic guided lean and six-sigma approach to solve high rejection rate on part disposal at composite manufacturing for aircraft component industry. The approach is called PaDLeSS which is stand for Part Disposal reduction through Lean and Six Sigma. PaDLeSS is developed from the integration between lean and six sigma tools with a guided by R-DMAIC-S approach and it is focused on the reduction of parts disposal mainly at a composite manufacturing panel for aircraft components. Since a unit price for one composite panel of aircraftcomponent is very high, a systematic approach to improve, control and sustain the process is necessary in order to reduce parts rejection rate in the process, outgoing process and at the customer process. PaDLeSS is devided into two main phases ; development phase and implementation phase. In a development phase, a thorough study was carried out from previous works and match with a requirement needed in part disposal reduction at composite manufacturing for an aircraft panel. The related data related to the parts disposal at the manufacturing line was also analyzed to get actual situation for improvement monitoring. Then, in the implementation phase, a few case studies selected at company A (composite panel for aircraft manufacturing company in Malaysia) for verification and validation purposes. In this paper, the development of PaDLeSS will be presented.
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