Needs

Process not strong enough, with a big variability in the lead time and hours / person per plane:

• Light control of the subcontracted sets, what obliges to modify the assembly plan
• Deficient materials supply that implies time losses in searching pieces
• Difficult process to equilibrate as different parts of the plane are involved, and in many cases they are new developments in a big percentage of the plane

Solution

Starting from a strategic deployment in which the value chain is analysed, the main action lines are established:

• Guarantee and to control the entry conditions of the subcontracted sets in the FAL (Final Assembly Line)
• Guarantee the availability of needed materials for the assembly and to standardise its flow and location in the plant
• Equilibrate the operations dividing the final assembly in phases leak of the same length
• Eliminate the non controlled operations such as “adjust” from the operations chain

Results

Unresolved work hours at the elements entrance in the FAL:

• Starting situation: 1.500 hrs / plane
  • Final situation: between 0 and 100 hrs / plane
  • Hours/person per plane: 750 hrs / plane reduction
• Organise the assembly by phases reducing the interferences between different specialities inside the plane
• Pieces availability improvement at the assembly’s beginning: from 70 to 85%