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Representative illustration: A commercial and military flight simulator manufacturer needed to consolidate two buildings into one facility while raising productivity and shortening cycle time.

Case Study · Aerospace & Manufacturing

A commercial and military flight simulator manufacturer needed to consolidate two buildings into one facility while raising productivity and shortening cycle time.

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1Challenge

Redesign manufacturing, assembly and management systems to fit one facility instead of two (9,300 m² and 4,700 m²). Objective: improve productivity, shorten cycle time and improve profitability.

2Approach

  • Observed design, manufacturing and assembly across both buildings to find root causes and size the opportunity
  • Redesigned material flows, staging and processes with proprietary simulation software
  • Engaged all personnel, including the unionized workforce, from day one

3Results

>2.0:1

ROI, as measured by the client's finance team

2 → 1

Buildings consolidated into one facility

Zero

Disruption to ongoing operations

Completed over a year ago; the client remains very satisfied with the results.

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© USC Consulting Group 2026 | Aerospace & Manufacturing. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.