Case Study, Production Capacity Doubles at Aerospace Manufacturer

Production Capacity Doubles Following Redesign of Work Layout at Aerospace Manufacturer

Background

A worldwide French-owned conglomerate serving aerospace, marine, automotive, energy, and railway industries with surface treatment chemicals, adhesives, and coatings needed a work layout redesign for their plant. This particular plant services Fortune 500 aerospace customers at a nearby airport with surface treatment chemicals and coatings.

Solution

Firefly developed a flexible facility layout that improved the material flow for the two existing production lines while incorporating three new production lines with minimum capital and minimized explosion proof zone requirements. The full solution established replenishment pull systems and Kanban replenishment triggers for shelf-life dated products and explosive raw materials.

Results

As a result of the changes made, the new plant layout enables growth in the plant portfolio with a potential revenue increase of 30%. Setting up the lines also included strengthening process documentation to enable certification under the upgraded AS9100 Rev D.

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