General Aviation Manufacturer (U.S.)


Business Case
Innovative product, but can not meet market demand Poor operational capability created financial crisis

Actions
Developed lean capabilities across entire value stream, integrated departments, created learning organization

Results (2.5 years)
Before
11%
3100
0.82
50
$10.6k
~3-20 days
Metric
Market share
Hours/unit
Internal Safety
Internal Quality
Indirect materials/unit
Service parts lead time
After
41% (+273%)
1750 (-44%)
0.13 (-84%)
25 (-50%)
$6.3k (-41%)
1-5 days (-75%)


Summary
Achieved #1 position for airplane class in 2.5 years