Aerospace – Military complex electromechanical assembly & aftermarket: Creating a world class manufacturing facility
What We Did
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Business Diagnostic delivered through a series of client / consultant workshops
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Redefined the Make v Buy decision logic and redesigned supply chain
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Complete redesign of three assembly lines and consequent factory layout
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Redesigned material presentation and sub-assembly operations
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Developed factory move plan incorporating implementation of new cell layouts
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Provided CONSULTAVILA interim support to reinforce key skill requirements ahead of and during the move / implementation
Results
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30% reduction in floor space requirements enabling a smaller and more cost effective site
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Reduced build lines from three to two by improving material flow and increasing flexibility of operations
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Reduced capital spend required to achieve the relocation by 35% over pre-project baseline
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Cleared customer arrears and achieved customer delivery schedule
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Restructured supply chain and introduction of build kits reduced delivered items from 120 to 19 and eliminated waste associated with unwrapping individual piece parts
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Assembly time per unit reduced by 21% due to elimination of out of station rework operations
Background
FTSE250 PLC with significant aerospace and defence interests needed to move from a high cost and ageing manufacturing location. Existing site underperforming with an aged manufacturing structure and poor product flow. Significant customer arrears and high levels of customer dissatisfaction