$1 Billion Global Manufacturer of Aluminum Extrusions and Machined Products

• Launch of a complex new product was hampered
• Manufacturing process was unproven for run rate and/or tolerance
• Lacked an integrated production scheduling system
• A product cost system did not exist
• Lack of staff and technical expertise
• Management structure was unclear and undefined
• Lack of comprehensive action plan

• BBK initiated its launch management team
• Additional support, both technical and operational, was obtained in Welding, Quality, Engineering, Scheduling, Costing and Human Resources
• A detailed action plan was developed and implemented
• Capability and reliability of work centers were reviewed

• Productivity rates were improved for gauging, welding, repair, inspection and shipping
• Capability and reliability of work centers were significantly improved
• Procedures and systems were improved and documented
• Supplier achieved production rates necessary to meet customer ship requirements