Aviation Company

Operational Diagnostics

Anonymous $15B OEM aviation manufacturing company

PROBLEM

This anonymous company had stagnant improvements across the organization while the competitive market was steadily increasing in high end business aircraft. They were struggling with stock price stagnation and volatility. The organization and leadership wanted to know 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%
  • Project First Year Benefits/Cost = 5,900%
  • Created Model for rest of company