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Lean implementation in helicopter assembly with lead time reduction by 20% and capital reduction by 35%

Client situation & approach

One of the leading worldwide helicopters manufacturer, with 5,000 employees, which was not able to respect promised delivery times and avoid high extra-costs due to the request of shorter delivery time, an increase in complexity of configuration and the high costs of late configuration. In this scenario, EFESO was asked to:

  • conduct an analysis of actual flows and loss intelligence
  • implement a new process-oriented organization (lean “engineering to order”)
  • perform a modelling of workload and queues in engineering department
  • define effective planning based on configuration


  • Stability by the introduction of lean in engineering
  • Improved reliability of planning and visibility of losses upfront
  • Lead time reduction of 20%
  • Working capital reduction by 35%