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Representative illustration: A U.S. trailer and truck body leader wanted to grow truck body market share, but material delays, rework and high WIP held it back.

Case Study · Aerospace & Manufacturing

A U.S. trailer and truck body leader wanted to grow truck body market share, but material delays, rework and high WIP held it back.

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1Challenge

Sub-assemblies built in the trailer plant caused priority conflicts and schedule instability, quality defects added WIP, and the baseline data was unreliable.

2Approach

  • Set up heijunka boards across sub-assemblies to create a traceable pull system
  • Built an area readiness tracker and a standard leadership agenda to flag risks early
  • Added completion checklists, quality checks and standard work to cut rework

3Results

118%

Throughput increase (11 to 24 units/week)

71%

WIP reduction (131 to 38 units)

83%

MOS audit compliance

Fewer labor hours per invoiceable unit, driven by quality and scheduling gains.

Manufacturing →Automotive →

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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.