Realization



Overview

 BeforeAfter

Electrical Power Transmission, Engineer-to-Order
  • Throughput was 300 bays per year.
  • Throughput increased to 430 bays per year.

Power Transformers,
Engineer-to-Order
  • Engineering cycle time was 8 months.
  • On-time delivery was 85%.
  • Engineering cycle time reduced to 3 months.
  • On-time delivery improved to 95%.
  • 16% increase in manufacturing throughput (revenues).

Transformer Repair and Overhaul
  • 42 projects completed in 2007.
  • On-time delivery was 68%.
  • 54 projects completed in 2008.
  • On-time delivery improved to 83%.

Theme Park Design, Install and Commissioning
  • 121 projects completed in 2004.
  • 142 projects completed in 2005.
  • 153 projects completed in 2006.

Next Generation Wireless Technology Product Development
  • Cycle time from first silicon to production for 1st generation was 19 months.
  • Cycle time from first silicon to production for 2nd generation was 8 months.

Material Handling Solutions, Engineer-to-Order
  • Completed an average of 6.9 projects per year.
  • Completed 10 projects in first 8 months of 2009.
  • 31% increase in throughput-dollars.

Telecom Switches Design, Development & Upgrades
  • 300-400 active projects with 30+ deliveries a month.
  • Lead times were long.
  • On-time delivery was poor.
  • Throughput increased by 45% per person.
  • Lead times shortened by 10-25%.
  • On-time delivery improved to 90+%.

Customized Software Development
  • Growth was stagnating, becoming insufficient to secure market position.
  • Throughput increased by 14% in the first 6 months.
  • Cycle time reduced by 25% and project completions increased 17% with over 90% on-time delivery.

Customer Experience Systems Customized SW Development for Telecommunications
  • Market pressure to reduce cost and cycle time.
  • 8 projects in crisis requiring CEO level attention in 2007.
  • 14% increase in revenue/man-month.
  • 20% reduction in cycle time.
  • 0 projects in crisis in 2008.

Helicopter Maintenance, Repair and Overhaul
(For Flight Schools)
  • Maintenance workload increased by 37% and turnaround times were long, leading to helicopter shortages.
  • 32% reduction in CH-47 turnaround time.
  • 52% reduction in UH-60 turnaround time.
  • 8 aircraft returned to customer ($90M in cost avoidance).
  • 18,000 sq ft of hangar space freed up ($2M in cost savings).

Iron Ore Asset Development Projects
  • 25,800 man-hours of engineering design work had to be completed in 8 months.
  • Historical delays of 2 weeks and man-hour overruns of 20%.
  • Project finished 3 weeks early.
  • Productivity increased by 25% with only 19,500 man-hours needed.

Satellite Design and Assembly
  • Reflectors were the constraint in Antenna and Satellite delivery.
  • Electronic units were late, delaying Satellite subsystems.
  • Classified Government program was behind schedule and losing money.
  • Operation was losing $200M a quarter.
  • Doubled Reflectors throughput and reduced cycle time by 28%, alleviating delivery constraint.
  • Increased productivity in Antenna Assembly and Test by 64% and subsequently another 26%.
  • Reduced cycle time for Electronic units, allowing subsystems to finish 30% faster.
  • Stabilized schedule and returned money to Government 4 quarters in a row.
  • Operation turned profitable.

Nuclear Power Engineering
  • Due-date performance was 60%.
  • Due-date performance increased to 95%.
  • Throughput increased by 30%.

IT Projects
  • 15 SAP functionality projects were completed per month.
  • SAP functionality project completions increased by 30% to 20 projects a month.

Nuclear Power Engineering
  • 19 design evaluation and modification projects were being completed per month.
  • Throughput increased by 25% to 24-30 projects per month.

Automotive Product Development
  • Cycle time for prototype builds was 10 weeks.
  • Cycle time for prototype builds reduced to 8 weeks.

Biotechnology Plant Engineering
  • 20% projects on time.
  • 87% projects on time.
  • 15% immediate increase in throughput.

Aircraft Engine Repair and Overhaul
  • 476 engines produced per year.
  • 4-8 weeks piece-part cycle time.
  • 60 days landing gear turnaround time.
  • 586 engines produced per year (23% increase).
  • 30% reduction in engine turnaround time.
  • 15 days piece-part cycle time (70% reduction).
  • 25% increase in throughput.
    30 days landing gear turnaround time (50% reduction).
  • $60M monetized in assets from reduced turnaround time.

 

Ongoing improvement:

  • 10 days piece-part turnaround time (30% further reduction).

Pharmaceutical New Product Development
  • 6 projects completed in the first 12 weeks.
  • 20% projects on time in 12 weeks.
  • 85 global generics and PSAI filings in 2009.
  • 85 product launches in 2009.
  • 915 days cycle time for full development in 2008.
  • 11 projects completed (83% increase).
  • 80% projects on time (60% increase).
  • 110 filings in 2010 (30% increase).
  • 149 launches in 2010 (75% increase).
  • 563 days cycle time for development in 2010 (40% faster).

Semiconductor Design and Manufacturing
  • Actual cycle time of projects was 38 months; 25% of projects were on time.
  • Actual cycle time reduced to 23 months; almost all projects are within the committed cycle time of 24 months.

Telecommunications Network Design & Installation
  • On-time delivery was less than 75%.
  • Average cycle time was 70 days.
  • Increased on-time delivery to 98+%.
  • Average cycle time dropped to 30 days.

Manufacturing Plant Construction
  • 11 months industry standard project duration.
  • 7 months to project completion (55% additional revenue 4 months earlier).

TGV Station Construction
  • 6 months left to deliver, and project was 5 months late.
  • Completed 11 months of work in 6 months.
  • Project on time (€5 M penalty avoided).

Helicopter Manufacturing and Maintenance
  • Only 33% projects completed on time.
  • On-time delivery increased to 83%.

Aircraft Upgrade and Repair
  • 5 aircraft on station.
  • Cycle time of 165 days.
  • 3 aircraft on station, 2 aircraft returned to Air Force, a replacement value of €300 M.
  • 15% cycle time reduction, 15% increase in output with 13% fewer resources; 22% reduction in support shops' cycle time.

New Product Development For Home Appliances
  • 34 new products per year.
  • 74% projects on time.
  • Increased throughput to 52 new products in the 1st year, and to 70+ in the 2nd year, with no increase in head count.
  • 88% projects on time.

CPG New Product Development
  • 150 projects per year.
  • 90% on-time delivery.
  • 20% faster time-to-market.
  • 98% on-time delivery.
  • 10% of projects finished ahead of schedule.

Digital Camera Product Development
  • 6 cameras launched in 2004.
  • 1 camera launched in spring window.
  • 1 out of 6 cameras launched on time.
  • 15 cameras launched in 2005.
  • 7 cameras launched in spring window.
  • All 15 cameras launched on time.

Engineer-to-Order
  • 84 days overall cycle time.
  • 24 days production cycle time.
  • 15 machines in 8 months was highest throughput ever.
  • 64 days overall cycle time (25% reduction).
  • 10 days production cycle time (60% reduction).
  • 22 machines in 5 months (47% higher throughput).
  • 22% improvement in EBIT.

Oil & Gas Platform Design & Manufacturing
  • Design Engineering took 15 months.
  • Production Engineering took 9 months.
  • Fabrication and Assembly took 8 months.
  • Design Engineering takes 9 months.
  • Production Engineering takes 5 months.
  • Fabrication and Assembly takes 5 months with 22% improvement in labor productivity.

ASIC Design Technology Development
  • 74% projects on time for small projects.
  • Major tool releases were always late.
  • 85% of small projects on time.
  • Major tools released on time for three years in a row.

Advertising Product Development
  • Completed 7 projects in 2006.
  • Completed 7 projects in the first 8 months of 2007.

High Tech Medical Product Development
  • 1 software release every 6-9 months.
  • Predictability was poor on device programs.
  • 1 software release every 2 months.
  • Schedule slips on device programs cut by 50%.

High Tech Medical Product Development
  • Device projects took 18 months on average and were unpredictable.
  • Development cycle time reduced to 9 months.
  • On-time delivery increased to 90%.

Food Preparation & Packaging
  • 72 sales projects completed per year.
  • 171 sales projects completed per year.
  • 52% increase in throughput-dollars.

Process Manufacturing Plant Engineering
  • 6 months cycle time for furnace design.
  • 45 projects/year engineering throughput.
  • 2.5 months cycle time (58% faster).
  • 60 projects/year throughput (33% increase).

Pharmaceutical Product Development
  • In 2005, completion rate was 5 projects/quarter.
  • 55% of projects delivered on time.
  • In 2008, completed 12 projects/quarter.
  • 90% on time, with same number of resources.

Train Maintenance, Repair and Overhaul Engineering
  • 16 months delay in delivery of last order.
  • 1 order executed at a time.
  • 100% on-time delivery on all orders.
  • 3 orders executed in the same time frame.

Marketing/Publishing Support
  • Projects were always late.
  • Lead times were not acceptable.
  • On-time delivery improved by 30%.
  • Lead times reduced by 25%.

Electric Generator Engineering
  • 110 projects completed in 11 months.
  • Low overall throughput.
  • 128 projects completed in 11 months.
  • 30% increase in overall throughput.
  • 44% increase in non-project throughput.

Engineered-to-Order Steam Generators
  • 20 casings per year.
  • 60% on-time delivery.
  • 27 casings per year (30% increase).
  • 90% on-time delivery.
  • 20-30% faster cycle time.

Garment Design
  • Product ranges were late to market.
  • 100% due-date performance.
  • 30% reduction in lead times and sampling costs.

Aircraft Engineering
  • 12 months was best case engineering cycle time.
  • On track to finish pylon project in 7 months.

Plant Maintenance and Upgrade
  • 300-500 days for boiler conversion.
  • Routine maintenance took too long.
  • 11 days planned for shutdown.
  • $2M revenue generated per day.
  • 120-160 days completion time (68% faster).
  • 10-33% reduction in 2007 cycle time.
  • 5-33% additional reduction in 2008 cycle time.
  • 8.8 days shutdown achieved.
  • $4M revenue gained.
    Set net operating hours industry record (6690 hours per year).

Defense Products Design and Manufacturing
  • Long project cycle times with frequent delays.
  • Difficult to synchronize Design and Manufacturing.
  • Project cycle times reduced by 20%.

Automotive Assembly Systems, Engineer-to-Order
  • 70% of projects were late.
  • High overtime and outsourcing.
  • Lateness reduced by 50%.
  • 63% gains in productivity.
  • 15% more projects completed.

War fighter Systems Testing
  • Long cycle times.
  • Low utilization of resources.
  • Poor visibility of project slips.
  • 30% reduction in cycle time measured over 900 projects.
  • 30% improvement in resource utilization.
  • 88% on-time delivery performance.

Aircraft Maintenance, Repair and Overhaul
  • 33 aircraft throughput in FY09.
  • 36 aircraft on station.
  • 44 aircraft throughput in FY10 (33% increase).
  • 24 aircraft on station, 12 aircraft returned to Air Force.

Aircraft Repair and Overhaul
  • Turnaround time 162 days.
  • 7 aircraft in repair cycle.
  • Turnaround time reduced to 115 days.
  • 4 aircraft in repair cycle (3 returned to customer).
  • Production output increased from 185 hours/day to 273.
  • 1 ½ dock spaces freed up (additional revenue potential $35M).

Aircraft Upgrade and Repair
  • Produced 11 aircraft a year.
  • Cycle time of 225 days.
  • Produced 17 aircraft a year.
  • Cycle time of 195 days.

Aircraft Upgrade and Repair
  • 4 aircraft on base.
  • Cycle time of 183 days.
  • 2.6 aircraft on base on average.
  • Cycle time of 155 days.
  • 11% capacity released for additional workload.

Aircraft Maintenance, Repair and Overhaul
  • Average turnaround time was 327 days.
  • Average turnaround time reduced to 146 days.
  • 44% increase in throughput from Q4 2008 to Q4 2009.

Aircraft Engine Repair and Overhaul

Engine piece-part repair:

  • 137 days backshop cycle time.
  • 260 parts/month backshop throughput.


Engines and Modules:

  • 45 modules/month throughput.
  • 18 days cycle time.

Engine piece-part repair:

  • 42 days backshop cycle time (69% reduction).
  • 434 parts/month throughput (67% increase).

 

Engines and Modules:

  • 50 modules/month throughput (10% increase).
  • 8 days cycle time (55% reduction).

Aircraft Upgrade and Repair
  • Throughput of 178 hours per aircraft per day.
  • Turnaround time 46-180 days.
  • Mechanic output was 3.6 hours per day.
  • 25% increase in throughput.
  • Turnaround time reduced to 37-121 days.
  • Mechanic output increased to 4.75 hours per day.
  • 40% reduction in overtime.

Aircraft Repair and Overhaul
  • Turnaround time 240 days.
  • 13 aircraft in repair cycle.
  • Turnaround time 160 days.
  • 7 aircraft in repair cycle.
  • 75% fewer defects.

Helicopter Maintenance, Repair and Overhaul
  • Throughput of 5.4 aircraft per month.
  • Throughput for Black Hawk was much lower than required.
  • Turnaround times were unacceptable.
  • Work scope per aircraft was increasing.
  • Throughput increased to 6.3 aircraft per month.
  • Black Hawk throughput increased by 40% in just 6 months.
  • 50% reduction in Apache turnaround time.
  • 15% reduction in CH47 turnaround time.
  • 15% reduction in Pave Hawk turnaround time despite increased scope.

Processing of Purchase Requests
  • Long delays in processing requests.
  • Long cycle times.
  • Delays reduced by 40%.
  • 76% reduction in cycle time.
  • 29% increase in throughput.

Army Vehicles Maintenance and Repair
  • Repair cycle time for MK48 was 168 days.
  • Repair cycle time for LAV25 was 180 days.
  • Repair cycle time for MK14 was 152 days.
  • Repair cycle time for LAVAT was 182 days.
  • Repair cycle time for MK48 reduced to 82 days.
  • Repair cycle time for LAV25 reduced to 124 days.
  • Repair cycle time for MK14 reduced to 59 days.
  • Repair cycle time for LAVAT reduced to 122 days.

Aircraft Repair and Overhaul
  • Average turnaround time for H-46 was 225 days.
  • Average turnaround time for H-53 was 310 days.
  • Throughput was 23 aircraft per year.
  • Reduced H-46 turnaround time to 167 days, while work scope was increasing.
  • Reduced H-53 turnaround time to 180 days.
  • Delivered 23 aircraft in the first 6 months.
  • Throughput increased to 46 aircraft per year.

Submarine Maintenance and Repair
  • Job completion rate was 94%.
  • On-time delivery was less than 60%.
  • Cost per job was $5,043.
  • Job completion rate increased to 98%.
  • Increased on-time delivery to 95+%.
  • Reduced cost per job to $3,355, a 33% reduction.
  • Overtime dropped by 49%, a $9M saving in the first year.

Aircraft Maintenance and Upgrades
  • Produced 6 aircraft in 2008.
  • Produced 9 aircraft in the first 9 months of 2009.

Custom Furniture Design and Manufacturing
  • Struggled to complete 200 projects per year.
  • Revenues were flat, business was just breaking even.
  • Completed 334 projects in the first 9 months.
  • Revenues increased by 88% and profits by 300%.

Equipment for Manufacturing Solar Panels, Engineer-to-Order
  • Revenues of €130 M. Profits of €13 M.
  • Cycle time was 17 weeks.
  • On-time delivery was 80%.
  • Revenues of €170 M. Profits of €22 M.
  • Cycle time reduced to 14 weeks.
  • On-time delivery improved to 90%.

Process Plant Turnaround (Nickel Smelting)
  • Projects were late and over budget.
  • Project 1 delivered on time.
  • Project 2 delivered 1 day earlier (with 10% extra scope).
  • Actual cost was 96% of planned budget.