Flight Path to Performance – Streamlining Operations for an Aerospace Manufacturer in Crisis

Background:

Crossover partnered with a US-based aerospace manufacturer of machined turbine engine components to address serious operational breakdowns. The mandate: stabilize subcontract throughput, restore delivery performance, and increase shopfloor output – all while transferring responsibilities to a new permanent Subcontract manager and preserving team morale. The engagement focused on optimizing throughput by redesigning facility layouts, standardizing processes, upgrading systems, establishing performance metrics, and delivering targeted team training.

Critical Issues:

• 97% of committed delivery dates missed, causing major delays and eroding customer trust.
• Severe bottlenecks in subcontract throughput
• Non-standardized workflows across the subcontract operation
• Inefficient facility layout restricting flow and productivity
• Outdated systems and no real-time performance visibility
• Inconsistent team performance due to training gaps
• Urgent need to transition knowledge and accountability to new leadership

Approach:

Crossover conducted a comprehensive review of the client's operations to uncover improvement opportunities across the entire value chain.

Our approach — built trust through hands-on support, active listening, and quick wins—prioritizing the team’s well-being while guiding steady, sustainable progress.

Key Actions:

• Reorganized the shop floor layout to optimize workflow and accommodate workload demands.
• Introduced “HOT” job boards to enhance team prioritization and streamline communication.
• Added pack stations and duplicated critical tools to meet peak production needs.
• Collaborated with Purchasing and Quality to implement a POS release process for to ensure on-time material availability.
• Strategically managed workloads to protect operational and workforce stability.

Results:

• Shipping and receiving throughput accelerated significantly
• Weekly job shipments and intakes increased to meet customer demand.
• On-time delivery performance improved, restoring customer confidence
• S Reclaimed floor space enabled greater agility without capital expansion