Aerospace and Defense Program


About the opportunity

The client designs, engineers, manufactures, repairs and overhauls a broad portfolio of aviation and industrial components, accessories, subassemblies, systems and aircraft structures. The client partners with original equipment manufacturers (OEMs) and operators of commercial, regional, business and military aircraft worldwide, to provide products and services that solve their hardest problems.
The client participates at all levels of the aerospace supply chain – from single components, to complex systems, to aerospace structures and their contents. The client provides solutions for the entire product life cycle of an aircraft – from raw material to aftermarket service.

The Challenge

The defense program’s operation was relocated to a new facility. The program had a challenging transition due to:

• Significant portion (approx. 80%) of workforce did not relocate
• New employees had tough learning curve
• Quality defects increased
• Began to fall behind on schedule
• Customer brought additional resources to support


We identified opportunities in the program and used a three-phase approach:

• Phase 1 – Workplace organization: We focused on eliminating excessive motion by mechanics due to a disorganized work environment.
• Phase 2 – Standardization: We began implementing standard work on key processes where there was risk due to problems in quality, cost, and/or cross training.
• Phase 3 – Quality Improvement: In the last phase we focused on specific problems affecting the quality of the finished product.


Our involvement lasted just short of a year in which we helped reduce:
• MRB WT tags generated / shipset by 44%
• Open Non-conformances by 66%
• Cumm Hrs behind schedule by 24%

About Us

We help manufacturers achieve and sustain operational costs reductions of 20%+, improve on-time delivery to 99%+, and reduce defects to improve product quality to 99%+. These changes help our clients grow company profit margins by up to 25%.
We have developed and used a proven approach to ensure manufacturers achieve and sustain significant performance improvement. Our consultants have over 15 years of experience working with manufacturers and developing their capabilities.
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