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Representative illustration: A bar-support maker for construction faced frequent breakdowns on aging equipment, high turnover and weak shop-floor control.

Case Study · Aerospace & Manufacturing

A bar-support maker for construction faced frequent breakdowns on aging equipment, high turnover and weak shop-floor control.

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1Challenge

Old equipment broke down despite routine maintenance, frustrating staff and feeding turnover. Shop-floor controls had lapsed and shift handovers broke down.

2Approach

  • Built a production MOS and a maintenance MOS over a 19-week project after a short feasibility study
  • Started at one work center and ran fishbone (5M) sessions with supervisors across shifts
  • Added certified operator training and rebuilt PM from 12 months of work-order history

3Results

13%

Improvement to date (target 20–25%)

19 wks

Project length

2nd

Follow-on project: SIOP and sister sites

Supply-chain constraints held gains below target and led to a follow-on SIOP project.

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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.