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Representative illustration: An energy-generation custom manufacturer facing regulatory surveillance, an 18-month-late growth project and a swing from $76M profit to a $33M loss needed a turnaround.

Case Study · Aerospace & Manufacturing

An energy-generation custom manufacturer facing regulatory surveillance, an 18-month-late growth project and a swing from $76M profit to a $33M loss needed a turnaround.

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1Challenge

Inaccurate heat-treat records led to 'Enhanced Surveillance' by a national regulator; LD exposure exceeded $300M. Foremen were not in a PDCA cycle (productivity 40–50%) and 50% of work was first-of-a-kind.

2Approach

  • Goal: stabilize the business, improve productivity and on-time delivery, cut cycle time and WIP
  • Closed MOS gaps and engaged foremen and associates in PDCA-based supervision
  • Introduced a new process to manage first-of-a-kind (FOAK) work

3Results

2x

Productivity, to ~85%

>0.95

Schedule performance

50→25%

Work in FOAK status

$18.4M

Turnaround; at break-even vs. budget

Liquidated damages exposure reduced and new business won.

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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.