Client’s Industry: Light Aircraft Rebuild, Repair & Modification

Project Trigger: Low profitability and risk of insolvency

Delivered Scope: We worked on this project as operational efficiency experts alongside a team of experts from the finance, HR and marketing fields. Our scope of work, primarily focused on floor efficiencies. Initial assessment revealed tremendous opportunities existed to streamline the work on the floor by taking a critical look where time and resources were wasted. We adopted a lean-philosophy-inspired approach which involved training client’s supervisors on the principles of lean operations and coaching a pilot 5S event. Later, the consulting team expert in charge of finance sought our help in creating a method and procedure to allow for an objective measurement of inventory accuracy, which we did.

Value & Impact: The company became showing signs of recovery in two months and went into the black in less than five months. Our 5S initiative was replicated in the two aircraft hangars and contributed enormously to efficiencies on the floor. Among others, the average stay time of an aircraft, of a reference job, was cut by approximately 25%. Improving inventory accuracy also meant that less stockout-caused delays were experienced.