Lean Transformation for Airplane Fan Blade Repair and Overhaul
Industry: Aerospace
Company Size: < 10,000 employees
Ownership: Private Equity
The Challenge:
Batch‑and‑queue processes, excessive WIP, poor material flow, and weak scheduling drove long cycle times and missed delivery targets in a high‑margin business.
Value Stream Mapping: Identified bottlenecks and incapable processes.
Future State Design: Developed greenfield and brownfield concepts with simulations.
One‑Piece Flow: Transitioned from batch processing to takt‑based flow.
Lean Training: Built foundational Lean capability across leadership and operations teams.
Our Approach:
40% reduction in order‑to‑ship cycle time
95% on‑time delivery
$5M reduction in WIP inventory
Greenfield facility recommendation (opened December 2024)
The Results:
Why It Matters
Streamlined production improves delivery performance, reduces cost, and enables scalable growth in a competitive aerospace market.
Services & Tools: Value Stream Mapping, Kanban, Visual Management, Lean Layout, 3P, Material Flow Simulation, Lean Training, A3 Problem Solving
