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Accelerating throughput to meet increasing demand (CS291)



This story is for CEOs who

  1. Are Interested in increasing throughput and driving operational excellence

  2. Want to reduce overruns, nonconformance, and waste

  3. Want to increase their company’s overall manufacturing operations maturity

The Challenges 

A major innovator is known for developing and manufacturing composite parts for autonomous systems, helicopters, business aircraft, refueling systems, and propulsion systems for the aerospace and defense industry. They ran two manufacturing plants to support engineering development activities. As a result of their design success, the company had to initiate and ramp up three major production programs which would more than triple their manufacturing requirements over the next 2 to 3 years.

Analyzing and assessing operations to create customized playbook for high ROI initiatives


SGS Maine Pointe:

  • Identified and prioritized improvements to shop floor, engineering, data analytics, advanced planning and scheduling (APS), change management, and cross-functional alignment, allowing the client to save over 11,650 hours, a 33%-40% reduction across multiple workstreams
  • Explored initiatives to increase capacity, communication, and efficiency in existing space
  • Identified ways to reduce waste and downtime, including Lean processes and preventive maintenance
  • Provided a TVO roadmap for increasing maturity of operations and boosting throughput to support achieving their 3-4x demand improvement

Lessons learned for other executives

  • Objective analysis reveals root causes and allows for data-based decisions
  • Determining which initiatives to pursue requires weighing many factors, including the degree of implementation difficulty and potential for sustainability
  • Total Value Optimization (TVO)TM is a valuable process to drive increased throughput

The Results

  • Engaged over 90 personal covering the entire, enterprise- wide value chain, including manufacturing, engineering, quality, production control, continuous improvement, program management, EHS, supply chain and technicians
  • Leveraged various qualitative and quantitative methods to identify >100 improvement opportunities categorized into 19 initiatives
  • Developed implementation roadmap to improve throughput across two manufacturing plants, enabling operations to accommodate 3X+ growth projections
  • Established KPIs, benchmarked against industry best practices, and recommended visual tools for managing and tracking performance
  • Introduced Total Value Optimization (TVO)TM strategies for upgrading operations maturity
  • Prioritized value creation opportunities and developed a journey map for implementing the findings over 18-month timeframe

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