Accelerating throughput to meet increasing demand (CS291)

Written by Maine Pointe | Jan 30, 2024 3:37:25 PM

This story is for CEOs who

Are Interested in increasing throughput and driving operational excellence
Want to reduce overruns, nonconformance, and waste
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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