Case Studies

BAE Systems Case Study

General Description

  • Industrial Engineering Support
  • Analyze current state and implement cost savings based on future state plan
  • Develop, train and implement Production System


  • 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 internalWIP by $5 million
  • Launched new automated paint system


Savings for the customer totaling over $5,000,000

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