Fortune 500, tier 1 aerospace manufacturer


This customer needed to reduce the cost, lead time and the supply risks associated with the production of a part that involved extensive outsourcing.  The product, which had a costly and complex workflow that required the outsourcing of multiple processes, was a fan for an aerospace application.


The customer-directed workflow for this fan included seven cross-country trips to five different vendors — including Allegheny Performance Plastics, who touched the fan three times. Allegheny Performance Plastics suggested and conducted value stream mapping on the entire part family, leading to the outsourced production of the metal insert and a balancing operation being moved to Allegheny Performance Plastics. 

With the in-sourcing of CNC machining of the inserts and balancing, five of the steps are now performed by Allegheny Performance Plastics — the other in-house processes included injection molding, analysis and testing and inspection.  The only remaining outsourced steps are plating the metal insert and burst testing — both of which were moved to suppliers nearby to Allegheny Performance Plastics Pittsburgh location. 

Allegheny Performance Plastics also developed a new analytic technique to validate the manufacturing lot — instead of interrupting production to await destructive test results, which further streamlined the production process. 


With no design change, Allegheny Performance Plastics was able to eliminate about 45 days of lead time (40% reduction), deliver $20,000 of annual savings and significantly reduce supply chain risk.