Case Study: Aerospace Systems Manufacturer → VDS Consulting

Case Study:

Value Driven Solutions' Impact on a Leading Aerospace Systems Manufacturer

Client Overview:

Company: Aerospace Systems Manufacturer
Industry: Aerospace
Specialty: Life Support Products for Regional, Commercial, and Military Aircraft
Annual Revenue: $350 Million

Project Overview:

Objective: To transform the operational efficiency and lean capabilities of a major life support systems manufacturer serving the aerospace sector.
Project Duration: 12 months

Challenge

The client faced significant challenges in managing a large, 250,000 square foot manufacturing site. High levels of inventory were causing inefficiencies in production flow and excessive costs. Additionally, there was a need to align the leadership team with modern operational excellence and lean manufacturing principles to sustain competitiveness and meet the demands of the aerospace industry.

Solutions:

Site Redesign:
- Redesigned the entire 250,000 square foot manufacturing facility to streamline operations.
- Developed a strategic vision for the site with clearly defined milestones for 1, 3, and 5-year goals.
Inventory Reduction:
- Implemented robust lean manufacturing techniques to reduce inventory by $90 million, significantly lowering holding costs and freeing up capital for reinvestment.
Executive Training:
- Conducted comprehensive training sessions for the executive team on lean transformations, focusing on continuous improvement and waste elimination.

Tools Used

Strategy Deployment: Employed to ensure all levels of the organization were aligned with the strategic objectives of the redesign and operational improvements.
Cell Design: Utilized to optimize the layout of manufacturing cells for better flow of materials and work.
Line Balancing and Delivery: Ensured that each production line was balanced and efficient, reducing downtime and maximizing output.
Material Presentation: Improved the accessibility and organization of materials at point of use, which minimized delays and inefficiencies.
Stocking and Inbound Logistics: Streamlined to ensure a steady supply of materials with minimized inventory levels.

Results

The comprehensive lean transformation led by Value Driven Solutions resulted in a streamlined operation with significantly reduced inventory and enhanced operational efficiency.
The executive team is now fully equipped with the knowledge and tools to sustain lean operations and continue improving productivity and profitability.

Conclusion

This project exemplifies how Value Driven Solutions' expertise in operational excellence can drive significant improvements in the aerospace manufacturing sector. The company's future-focused approach not only optimized current operations but also prepared the client for sustainable growth and competitiveness in a challenging industry.