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Representative illustration: An industry-leading provider of advanced metallurgical products and inorganic chemicals needed to meet demand for a specialty alloy and digitize the process.

Case Study · Aerospace & Manufacturing

An industry-leading provider of advanced metallurgical products and inorganic chemicals needed to meet demand for a specialty alloy and digitize the process.

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1Challenge

Demand for an extruded specialty alloy could not be met even with 15–20% overtime. The CEO wanted the process digitized as a model for the organization.

2Approach

  • Applied lean process mapping and task analysis, cutting cycle time 3%
  • Moved maintenance from run-to-fail to a planned 8-hour block every 4 weeks
  • Supported a smart factory platform reporting 'machine truth' to workers

3Results

11%

OEE improvement

7%

Increase in asset availability

$1.7M

Improvement in gross margin

A digital 'machine truth' now connects workers to data.

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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.