Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Accelerating Aircraft Assembly Line Capacity through Hands-on Operational Optimization
Industry: Aerospace & Defense
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
A leading aerospace manufacturer employing over 100,000 people globally, specializing in the design and manufacture of high-complexity aircraft sections. The site involved in this study is a large-scale, high-mix, high-volume factory responsible for assembling the central fuselage sections of commercial aircraft.
The Challenge
The client was facing intensified demand, requiring an increase in monthly production rates from 54 to 63 aircraft—and potentially higher in future ramp-ups.
The existing pulse line assembly system was already struggling to sustain a 5-hour takt time at the current rate of 54.
The goal was to unlock new efficiencies across manufacturing engineering, product design and shop floor execution, enabling a sustainable rate increase while controlling costs and supporting business continuity.
Real Results Achieved Together
The operational transformation enabled a fundamental shift in production capacity through systematic bottleneck elimination and workload optimization. Working alongside client teams, we delivered sustainable improvements across the entire pulse line system.
Transformation Impact
- Identified clear pathway from rate 54 to rate 63 with quality maintained
- Developed scenarios for achieving rate 80 without new pulse line investment
- Improved workload balancing for smoother operational flow and better resource utilization
Related Services
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Facing Similar Aerospace Production Challenges?
• Struggling to meet increased demand without major capital investment in new lines
• Seeking to unlock hidden capacity through operational excellence and workload optimization
• Ready to transform your assembly operations through hands-on collaboration and proven methodologies
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