Background

Our client was launching an assembly line for a new product which was critical to the future of the company.  The product was a white sheet design meaning that every aspect of the product was new and would require certification and testing.  Our challenge was to improve the overall assembly line process and tools to enable reduced costs, improved quality and on time delivery.

Business challenge

Our challenge was to improve the overall assembly line process to enable reduced costs, improved quality and on time delivery.   The product was just finishing low rate production and the company was experiencing diffiuclty ramping up production to the required rates within budget.  Additionally, the new line was staffed with new operators, new tooling, new procedures and new managment.  

Solution

• Our team worked with the client to develop a new collaborative planning process to ensure smooth build at each shift.  The collaboration process used "Visusal Management" and tools to provide clear direction and timing requirements for build
• Our team designed and deployed a new set of tools to support the assembly line operators, supervisors and management.  The tools provided real time information on status and key assembly drivers.  The focus was to highlight the "Waste" and ensure the support team was taking proactive measures.
• Our team devoped and delivered the initial training materials.  This was followed by developing expertise within the client to continue the deployment throughout the operation.

Results

• The station reduced the assembly hours by 45% from 1900 hrs to under 1000 hrs.  
• Out of station quality issues reduced by over 90%.
• The tools became the standard solution deployed throughout aircraft assembly.