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Case Studies: Train To Gain

 

Company Profile

Formerly Lucas Aerospace - York Rd.
Annual Turnover: £57m
No. of Employees: 378
Customers: Rolls Royce
Products & Processes: Design, development & manufacture of engine control & power systems.


Building on the Autonomous Module layout that was created in 1999, we needed a method of improving the process flow to improve quality, increase factory margin and make on-time delivery a natural occurrence rather than an effort.

We used VSM to show us the most effective flow of work through the module and identify areas of waste around which we could run further Kaizen events to eliminate it. This tool was used to maximum effect by involving people working in the value stream, as well as support areas, with the whole process facilitated by Industry Forum. We are now successfully rolling this methodology out to the other Autonomous Modules as part of a larger Improvement Programme."


Chris Plumb, Operations General Manager.

Board preparation

Post wave operations "Level 1"

Trent 800 unit on test


Activity Structure

LEC Sales Turnover by Product

Due to the complexity of the current process routing it was not possible to select a particular product family.

The VSM mapped all products.

Current State Capacity Chart (Monthly)

Future State Capacity Chart (Monthly)

Key activities necessary to move from the Current state to the Future State VSM