TBM applied lean principles to address these challenges, with key actions including:
A critical part with uneven throughput and long lead times raised concerns about meeting demand
Leader in the design, manufacture, and service of aircraft engines and auxiliary power units. Project was focused on addressing challenges related to high inventory levels, long lead times, and value-stream logistics (VSL) to drive better throughput and improve lead times.
results
solution
ChallengeS
Client
Delivery Performance
Achieved 100% delivery-to-requirement for the critical part
Inventory Reduction Inventory levels were reduced by 45%
Lead Time Stabilization Established a consistent daily flow of materials, steadying lead times
Conversion Cost Reductions
Work eliminated overtime costs, overproduction, pushing parts, and crisis management
Economic Production Increments Rationalized parts production into the most economical increments based on manufacturing processes
Steady Cadence
for Product Movement
Ensured products were moved at a consistent and predictable pace to minimize bottlenecks
Simplified Value-Stream Logistics
Redesigned logistics to reduce complexity and improve cost and lead-time performance
Standard Work
for Materials Flow
Developed and implemented standard work processes to streamline flow of materials
Pull vs. Push System
Transitioned from a push system to a pull system to align production with actual demand, reducing overproduction and excess inventory
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ChallengES
solution
results
High inventories of expensive parts were creating financial strain
The company was preparing to ramp up to meet volume increases with several new parts
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Operational flow impacted by long lead times and complex value-stream logistics
Applying Lean in Aerospace: A Case Study
TBM worked closely with an aerospace manufacturer to implement a lean transformation project aimed at reducing conversion costs, optimizing inventory, and improving delivery performance. Below are some of the highlights of the engagement and the result.
Client