for global airline caterer to meet top-down profitability target by transforming seven factories with focus on planning, manning, manufacturing and logistics. Applying Lean techniques to the operations value-stream allowed streamlining processes, delayering the organizational structure, balancing labor hours to demand, and connecting workstations to eliminate batching and create continuous flow. Productivity improvements delivered $5M annual savings, while one European warehouse could be closed. In the second phase of the program, best practices identified in Europe were translated into operating standards (SOP), and those transferred to factories in Asia, enlarging scope and impact of the cost reduction program.
Facts & Figures
- Industry: Airline Service
- Revenue: $2.4 billion
- Employees: 22,000
- Scope: Operations, Logistics
- Sites: 5 DE, NL, HK
- Project: 15 months
- Support: 300 days
- Role: Consultant
- Savings: $5 million
Client Feedback
"Good to see the commitment and acknowledgment of improvement opportunities and encouraging seeing first results already."
"The training was really good. I learned a lot from the value stream mapping exercise and see the operation now with totally different eyes."
"This session was incredible! In just one day, you helped everyone to get onto the same page, create a vision, and model the future state."
"Thanks for your very good summary and details. With this clear and open analysis as well as the very good suggestions for implementation as base, I have no doubts that you will manage to implement and get the site fully back on track."