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Representative illustration: A high-tech defense engineering firm lost managerial control after layoffs, as international expansion squeezed margins.

Case Study · Aerospace & Manufacturing

A high-tech defense engineering firm lost managerial control after layoffs, as international expansion squeezed margins.

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1Challenge

Early retirements drained senior knowledge. In a matrix structure, unreliable schedules caused programs to compete for parts and overload work preemptively.

2Approach

  • Ran root cause analysis with key managers to find costly delays and errors
  • Used Employee Involvement Prototype sessions to build commitment and gather ideas
  • Set up regular progress reporting and new metrics in engineering design services

3Results

121%

Increase in productivity

97%

Decrease in defects

50%

Decrease in WIP inventory

45%

Fewer drawings returned for rework

Also cut drawing cycle time 25%, build time 32% and raised on-time releases 40%.

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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.