Tier 1 aerospace customer.
A long-time customer asked Allegheny Performance Plastics to help with an existing manufacturing project. This fan had a high-cost, highly complex workflow that included outsourcing of multiple operations. Outsourcing created supply risks and protracted lead times.
Value stream mapping (VSM) was conducted on the entire part family. Previously outsourced production of the metal insert and a balancing operation were moved to Allegheny Performance Plastics, to be conducted in-house along with injection molding, CNC machining, analysis and testing, and inspection.
The team also developed a new analytic technique to validate the manufacturing lot (instead of interrupting production to await destructive test results), which further streamlined production.
- 10% cost reduction.
- 40% decrease in lead time.
- Minimized supply risk.