Aerospace Supplier - Precision Machined Parts
The client engaged us to provide an executable plan for increasing revenue and securing additional customers in the Aerospace and Defense Industry. They had 3 primary customers providing them with $24.5M of annual sales. After a one week evaluation, we developed a project which involved improving the process maturity of the supplier's key and critical processes, and at the same time put forth a road map to gain visibility and quality approvals from additional prospective customers. At the end of 6 months, the supplier had 50% of key processes documented at process maturity at level 3 (standardized) or above, was formally registered with 25 prospective "new" customers, and had received quality approvals from 6 new customers. They had received 12 RFQ's totaling $17M in value. In the 3rd quarter they won an RFQ bid, and received a multi year PO with total value of $33M over 5 years.
Defense Prime Contractor - Electronic Systems Fabrication
US & UK
The client approached us for help in analyzing their supply chain in composites and thermal plastics. They had on-time delivery issues, quality issues, and pricing fluctuations for "like" work product. They were buying from 6 different suppliers in 3 countries. Our first step was to visit the suppliers involved to perform an in depth assessment. The assessment pertained to the supplier's quality system, lean adoption, manufacturing capabilities and formal process maturity. The net result was that the client disapproved three of their suppliers and appointed one new supplier based upon our recommendations. Approximately 6 months afterwards, the sourcing category improved in OTD from 70% to 99%, and had a quality acceptance move from 48% to 95%. The estimated savings to the client was more than $18M in the first year.
Aerospace Tier One Contractor - Sub Assembly Manufacturing
We were referred to this Global Tier One Aerospace Contractor by one of their customers. They had quality and delivery issues in their sub tier supply chain. Much of the sourcing had been developed "off-shore" and involved 5 suppliers. Subsequent to an evaluation of each of the suppliers, we made some sourcing recommendations to the customer. This involved the client's supplier development team as well as some independent Lean/Flow practitioners supporting performance improvement projects at the supplier sites.. We also moved about 20% of the manufacturing to a new source. The estimated savings and improvements totaled more than 17% in the first year.
Defense Supplier - Complex Machining and Fabrication
This supplier had a need to increase it's customer base and revenues. They had more than 50% of their revenue from one customer and many of the customer's programs were at "end of life". Subsequent to an evaluation of the client's manufacturing capabilities, we embarked on a focused campaign of awareness within a targeted potential audience matched to their capabilities. After 6 months, the client had 7 new customer approvals and had received 4 RFQ's totaling approximately $4M. In the 8th month, the client had been awarded 2 P.O.'s for total of $2.1M.