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Representative illustration: A drivetrain and braking components maker growing 25% a year could not keep up with demand without large, costly inventories.

Case Study · Aerospace & Manufacturing

A drivetrain and braking components maker growing 25% a year could not keep up with demand without large, costly inventories.

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1Challenge

A rigid linear process relied on big WIP and finished-goods stocks. Engineering had a 12,000-hour backlog and preventive maintenance was 2,700+ hours behind.

2Approach

  • Prototyped a simpler welding process with welders and supervisors, removing a major bottleneck
  • Introduced cells, kanban, quality at the source and quick changeover on both assembly lines
  • Built a simple engineering work-management system and rebalanced uneven workloads

3Results

90%

Reduction in average cycle time

80%

Reduction in WIP inventory

118%

Improvement in weekly engineering plan attainment

72%

Reduction in mill changeover time

A continuous improvement mindset continues across the company.

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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.