Case Studies

BAE Systems

General Description

BAE Systems partnered with The Productivity Team (TPT) to enhance manufacturing efficiency, reduce costs, and implement a streamlined production system. Through advanced industrial engineering strategies, we analyzed the current state and developed a future-state cost-saving plan, delivering significant operational improvements.

Industrial Engineering Support

Analyze current state and implement cost savings based on future state plan

Develop, train and implement Production System

Scope

Developed Lean Training Program (included all salaried and hourly personnel)

Developed manpower reduction plan and reduced hourly direct labor from 232 heads to 95 equaling $4.8 million in savings

Went from 4 shifts to 2 shifts at 4 days/10 hours

Developed new layout and material flow plans and reduced internal WIP by $5 million

Launched a fully automated paint system, increasing efficiency and production capacity

Proven Results: Over $5 Million in Cost Savings

The implementation of TPT’s strategic industrial engineering solutions helped BAE Systems achieve:

  • $5 million in total cost savings
  • Improved workforce efficiency & labor cost reduction
  • Optimized production flow & reduced WIP inventory
  • Enhanced manufacturing processes with automation

Success!

Savings for the customer totaling over

$5,000,000

bae-systems

Other Case Studies

Bloom

Brammo Motorsports

Changan Ford