Pragmatic solutions for complex assembly processes in aviation

In the aviation industry, project-based processing of production tasks is very much to the fore. Especially companies that have little experience in series production must consistently drive forward the industrialization of production in the final development phases of an aircraft and achieve a paradigm shift from a project-based approach to stable operationalization. The company that we supported in achieving the ambitious unit volume targets in the assembly area faced an environment with difficult economic conditions 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 transport 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

Percentage of individual services

reactive situation stabilization
holistic concept development
risk analysis production performance

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

Optimization of assembly and supply chain for aircraft construction

Similar projects

We look forward
to hearing from you.