Operational Diagnostics

Anonymous $15B OEM aviation manufacturing company

Problem

- Stagnant improvements across the organization
- Increasing competitive market in high end business aircraft
- Stock price stagnation and volatility
- Organization and leadership wanting to show what could be achieved even in highly unionized team

Solution

  • Company struggled to see how lean could be applied to low volume custom products
  • Develop pilot learning model as lean example
  • Improve operational performance to meet customer OTD, lead time reduction customer options flexibility & beat competitor cost structure
  • Had not experienced lean/TPS and limited process/system improvement focus

Results

  • Received internal #1 Global Award of “Most Accomplished and Changed Culture”
  • WIP Inventory reduced -53%
  • Productivity improved -32%.
  • Production lead-time reduced -20%.
  • On-time Delivery improved from 70-80% to 100%
  • Project First Year Benefits/Cost = 5,900%
  • Created Model for rest of company

Operational Diagnostics

Anonymous $15B OEM aviation manufacturing company

Problem

- Stagnant improvements across the organization
- Increasing competitive market in high end business aircraft
- Stock price stagnation and volatility
- Organization and leadership wanting to show what could be achieved even in highly unionized team

Solution

  • Company struggled to see how lean could be applied to low volume custom products
  • Develop pilot learning model as lean example
  • Improve operational performance to meet customer OTD, lead time reduction customer options flexibility & beat competitor cost structure
  • Had not experienced lean/TPS and limited process/system improvement focus

Results

  • Received internal #1 Global Award of “Most Accomplished and Changed Culture”
  • WIP Inventory reduced -53%
  • Productivity improved -32%.
  • Production lead-time reduced -20%.
  • On-time Delivery improved from 70-80% to 100%
  • Project First Year Benefits/Cost = 5,900%
  • Created Model for rest of company