- Aerospace
Pragmatic solutions for complex assembly processes in aviation
In the aviation industry, project-based processing of production tasks is very much to the fore. Companies that have little experience in series production in particular must consistently drive forward the industrialization of production in conjunction with the final development phases of an aircraft and achieve a paradigm shift from a project-based approach to stable operationalization.
The company, which we supported in achieving its ambitious unit sales targets in the assembly area, was faced with a difficult economic environment and volatile dynamics in shareholder composition.
With a pragmatic approach, we very quickly created transparency about the potential for increasing output and immediately implemented various measures within the first few weeks. It was particularly significant that the measures ranged from changes to transportation and delivery processes to the integration of technical aids and the adjustment of shift models and coordination in the supply chain. Last but not least, a key aspect of the joint success was that the bottleneck situation was explained to top management in a targeted manner, combined with a set of long-term measures to stabilize output and the associated resource requirements.
Profile
Company size
Location
Worldwide
Period
1 year
Branch
- Aerospace
Percentage of individual services
Challenge
Lack of mindset on the relevance of increasing output in the lower hierarchy levels
Contractually and operationally insufficiently clarified agreements with suppliers
Lack of systematics in production planning
Unstructured planning and implementation of material delivery
Inadequate personnel deployment planning
Demanding customer specifications
Procedure
Value stream mapping to map the key processes
Workshops on bottleneck identification and resolution
Demand coordination Capacity depending on different program variants
Evaluation and prioritization of measures as well as continuous tracking
Adjustments to the organization (shift model revision, adjustment of competencies)
Content-related monitoring of the implementation of measures including proof of effectiveness
Results
Clear representation of the factory's volume limits
Scenario descriptions of different utilization states including resource requirements
Implementation of around 50 specific measures to increase efficiency and emissions
Increase in output by 150% within 10 months
Introduction of a new shift system including group work and efficiency bonus
Identifying bottlenecks at suppliers and focusing on key hot spots in the supply chain
The project in detail
Project Highlights
Top-down capacity requirement rejection
Continuous reporting across all hierarchy levels
Interlocking technical and organizational improvements
