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industry
Manufacturing

Upgrading an aerospace co.'s up-in-the-air processes​

Context

An aerospace casting manufacturer is facing rising demand while running production on Excel and Power BI without a true MRP system. Limited visibility into capacity, labor, and machine constraints makes planning difficult, schedules volatile, and bottlenecks unpredictable – leaving it difficult to meet future demand. To scale with confidence, they need clearer insight into inventory, capacity, and day-to-day execution.​

Value Created

Reliable visibility​
into inventory, staffing, and throughput
Integrated scheduling tools
for daily and weekly execution
Established accountability
through throughput, adherence, and performance metrics

People

VALUE LEVERS

  1. Improved confidence and decision quality for frontline teams and leaders
  2. Stronger cross-functional alignment around priorities and constraints
  3. Higher adoption and sustained use of new planning tools

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HOW WE DID IT

  • Trained all user groups (operators, planners, leaders) on how to use and interpret the tools in daily workflows
  • Embedded clear ownership and accountability tied to capacity, schedule adherence, and throughput
  • Shifted planning conversations from “reacting to issues” to “running to plan with facts”​

Process

VALUE LEVERS

  1. Predictable, repeatable production planning and execution
  2. Proactive identification of bottlenecks, backlog risk, and recovery needs
  3. Standardized daily and weekly operating rhythm

HOW WE DID IT

  • Designed standardized capacity planning and scheduling processes grounded in real constraints (labor, machines, inventory)
  • Created clear visibility into backlog, catch-up requirements, and tradeoffs before issues hit the floor
  • Established performance management routines using throughput, adherence, and execution metrics
  • Aligned planning cadences (daily, weekly, forward-looking) to demand and operational realities