This leading aerospace manufacturer faced significant cost challenges, coupled with supply chain quality issues and excess inventory. We worked closely with the Executive and Plant Management teams to develop the cost reduction strategy and translate it into executable projects to ensure delivery to the cost budget. To support this we also helped to define the continuous improvement organisational structure (MBB/BB/GB), key roles and accountabilities, and business unit Key Performance Indicators. Trained capability was then aligned to the project portfolio for execution. Our core competence of building capability whilst delivering tangible business value was then used to support the delivery of measurable fiscal benefits.
Additionally, working with the site leadership teams we supported the introduction of lean principles into the supply chain. This supply chain support included Value Stream Mapping to identify inefficiencies, Workplace Organisation (5S), Standard Processes and Compliance checking to reduce defects. We also instilled disciplines to monitor daily output performance, embedded a Preventative Maintenance Programme, drove core lean concepts such as OEE and SMED to increase delivery rate and reduce inventor on critical constraints.
Within 12 months the programme delivered £10m inventory reduction (circa 40%) and £12m in cost reduction through improvement activities.
