Turbomeca Process Improvement
Process Background
The Arriel engine is made up of five modules. The higher level operation has two processes. The first is the Prequote phase where the engine is stripped and assessed to determine what scope of engine maintenance and repair overhaul (MRO) is required. The second phase is Postquote final assembly the customer has agreed MRO activity to commence.
Objectives of KM&T Activity
Pre-quote lead time prior to the KM&T intervention was averaged at 90 days. KM&T were required to undertake a diagnostic of the Pre-quote process, highlight opportunities for improvement and implement solutions using Lean tools and techniques. The primary objectives were to decrease the lead time of the process, implement visual management to help control and manage the process and calculate capacity of process for future planning.
Actions
- A current state Value Stream Map (VSM) was created through facilitated team workshops
- Problem and Countermeasure process used to capture all concerns with process flow
- Concerns were prioritised and countermeasures implemented
- Remove double handling of parts and information at the first step of the process
- Introduce Pull system for WIP & Inventory throughout process
- Skills Matrix introduced to target skills gaps
- Visualisation boards to show production status
Results
- Pre – quote lead time reduced from an average of 90 days to 30 days
- 30% reduction in WIP
- Improved visualisation of planning activity
- Pull systems deployed
- Cross training completed to plan
Client Testimonial
“KM&T quickly assessed Turbomeca Australia’s immediate requirements, and efficiently helped implement an improvement plan that was achievable and more importantly repeatable”
Stewart Noel
Head of Production & Engineering
