The RE Method: A Simple Tool to Start Eliminating Waste

Every repeated check, duplicated task, or unnecessary step consumes time, resources, and attention, and if not properly justified, can create inefficiencies and increase the risk of errors. One of the most straightforward tools to tackle this type of inefficiency is the RE Method, a practical approach to reducing waste (non-value-added activities).

At its core, the RE Method is about spotting repetition. The prefix “re-” in Latin means “again,” appearing in words like repeat, reinspect, re-do, rework, reevaluate, or reprogram. In process improvement, any activity that duplicates effort, whether it starts with “re-” or includes terms like “check,” “verify,” or “ensure”, is a candidate for examination.

Identifying Waste Through Process Mapping

The RE Method works best when paired with visual process documentation. Tools such as process mapping allow teams to see the sequence of steps in a workflow, making it easier to spot duplicated tasks or unnecessary verification points. When the process map is clear, identifying repeated activities becomes a relatively straightforward task.

Once identified, these activities are analyzed based on MUDA waste types. In Lean, we distinguish between:

• MUDA Type I: Non-value-added but necessary activities, often required for safety, compliance, or regulatory reasons.

• MUDA Type II: Non-value-added and unnecessary activities that can be eliminated immediately.

For example, a second person inspecting the completion of a critical maintenance task, a co-pilot double-checking fuel calculations, and the approval of high-value or safety-critical equipment purchases are typically classified as MUDA Type I. These checks ensure compliance and safety, necessary safeguards in aviation.

On the other hand, tasks such as rechecking minor document details, like spelling errors or routine paperwork already processed by automated systems, are often MUDA Type II. Eliminating these steps can save time and allow your team to focus on more critical, value-adding activities.

It is important to note that knowing a second person or activity will take place can encourage greater diligence and accountability, but it may also lead to overreliance on the inspector or increased stress. Balancing these effects ensures that necessary repetitions enhance safety without introducing unnecessary inefficiencies. We will explore these psychological effects of repetition and oversight in more detail in a future article.

Practical Benefits in Aviation

Applying the RE Method in aviation operations offers tangible benefits:

1. Improved efficiency: By removing unnecessary duplicate tasks, teams can complete processes faster without compromising safety or compliance.

2. Reduced errors: Streamlining redundant steps reduces the chances of confusion or conflicting actions.

3. Enhanced focus on value-added work: Maintenance personnel, planners, and administrators can dedicate more time to tasks that directly impact aircraft safety, reliability, and operational performance.

For example, in a maintenance planning department, re-evaluating every minor document detail after automated systems have completed checks adds little value but consumes significant staff time. By applying the RE Method thoughtfully, eliminating only unnecessary repetitions, workflows become smoother, and resources are freed for tasks that truly matter, all while maintaining the strict safety standards required in aviation.

Despite the obvious benefits, its use must be done with careful consideration, given the safety-sensitive nature of the industry.

While the RE Method focuses on eliminating duplication, it works best as part of a broader process improvement toolkit. Techniques like process mapping complement the RE Method by providing a holistic view of the workflow.

A Simple Step Toward Continuous Improvement

The RE Method is deceptively simple but highly effective. By systematically identifying and eliminating unnecessary repetition, aviation organizations can save time, reduce frustration, and focus on high-value work, all without compromising safety or compliance.

While powerful, it addresses only a portion of the many inefficiencies that can exist across airline operations. Other types of waste, delays, bottlenecks, and unnecessary complexity require additional methods and tools for full optimization.

At The Lean Airline, we incorporate hands-on training in the RE Method as part of our Process Mapping and Analysis course, giving participants practical skills to apply these principles directly to aviation operations. From maintenance planning to crew scheduling, our courses help aviation professionals spot waste, streamline processes, and drive operational excellence. Start applying these tools today!