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Success Story

Operational Excellence in Aviation and Aerospace

Find out how a leading aircraft manufacturer is realizing millions in potential with TMG Consultants

The aviation and aerospace industry is characterized by extremely high quality requirements, complex supply chains, and intense cost pressure. In order to remain competitive in this dynamic environment, achieving, Operational Excellence is not just desirable, it is essential.

Continuous optimization of production, logistics and support processes is crucial for achieving economic efficiency and ensuring long-term viability.

Expert appointment for Aerospace
TMG 9 Industries 9 Aviation and aerospace 9 Success Story Aviation and Aerospace
Project description

Our customer’s challenge

Initial situation:
Despite its technological expertise and high capacity utilization, a long-established, global aircraft manufacturer faced insufficient margins and inefficient manufacturing processes. High process costs, particularly for high-volume products, resulted in declining margins and, in some cases, negative contribution margins. This reduced the company’s overall profitability.

Project objectives:
The overarching goal was to identify and realize comprehensive efficiency potential throughout the entire value chain, from parts manufacturing and assembly to underlying support processes such as industrial engineering, intralogistics, and mechanical engineering. After TMG Consultants conducted a “quick check” and identified an initial savings potential of €8.7 million, the comprehensive “Operations Excellence” transformation project was launched.

Systematically toward success

TMG approach and systematic implementation for sustainable success

To achieve these ambitious goals, TMG Consultants took a multi-stage, holistic approach that combined analysis, implementation, and employee empowerment. The project was divided into several core packages.

  • Production optimization: Detailed analysis and optimization of NC programs, implementation of new tool and clamping concepts, adaptation of production technologies, and reduction of setup times through SMED workshops. The goal was to achieve a sustainable reduction in process and manufacturing costs.
  • Assembly optimization: Conducting CIP workshops in the assembly lines to increase efficiency in the assembly processes. This involved optimizing and rescheduling the assembly processes, material provision, and overall material flows.
  • Optimization of engineering and support processes (ME, IE, QC): The value added in indirect areas, such as work preparation (IE) and mechanical engineering (ME), was analyzed using Live Process Records (LPR) to identify and eliminate waste. Quality assurance (QA) processes were also evaluated.
  • Coaching & training: To ensure the sustainability of the changes, managers and employees received intensive training and coaching. This promoted a new mindset focused on efficiency and anchored the optimized processes within the company.

 

The implementation was carried out by agile, multifunctional teams consisting of TMG consultants and customer employees in order to ensure maximum knowledge transfer and a high level of acceptance.

Facts instead of promises

We deliver measurable results that convince:
The added value for our customers

The consistent implementation of the “Operations Excellence” program led to impressive and quantifiable results across all areas examined:

​

Production efficiency

The potential identified by our consultants was fully realized in practice, and in some cases, it was even exceeded. In random samples of complex turned parts, targeted savings were achieved in the form of process time reductions of up to 78%. On average, process time reductions of 32.7% were demonstrated.
Process time reduction_Aviation and Aerospace_Customer success

Material cost reduction

By optimizing the use of raw materials and reducing waste, potential savings of over €1.47 million p.a. were identified in material costs alone.
Material cost savings_Aviation and Aerospace_Customer success

Process efficiency in support areas (ME, IE, NC)

The analysis of the engineering processes revealed an average efficiency potential of 26.7%. This corresponds to a freed-up capacity of 24 FTEs or annual savings of around €760,000.
Process efficiency_Aviation and Aerospace_Customer success

Optimization of quality control (QC)

By stabilizing the manufacturing and assembly processes, realigning the testing processes, and adjusting staffing levels, a 12% reduction in personnel was achieved in the area of operational quality assurance on the shopfloor.
Quality control_Aviation and Aerospace_Customer success
This project clearly demonstrates the potential of a structured consulting approach and partnership-based cooperation in the aerospace industry. Thanks to this project, our customer is now able to produce more profitably and strengthen its long-term market position.
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