Engagement Result

Major Command: Air Force Materiel Command (AFMC) - U.S. Air Force

Organization: Ogden Air Logistics Center (OO-ALC)

Group: 309th Commodities Maintenance Group (309 CMXG)

Project: Landing Gear Maintenance, Repair, & Overhaul (MRO) Process Improvement

Assignment: The 309 CMXG's MRO of landing gear was taking too long and placing stress on the supply chain. MainStream GS engaged to improve the flow of the "East Wall" feeder line which made repair determination and 'fed' the back shop operations to the various assembly lines. The goal of the project was to improve the assessment of the back shop repair in order to improve flow to the assembly lines of the various weapons systems landing gear.

Actions: MainStream GS conducted Steering Team Training with the 309 CMXG's leadership. Cross-functional teams were assembled to support the transformation process. MainStream GS trained leadership, functional support personnel, and the workforce in continuous process improvement (CPI) and Lean principles. In addition, we facilitated the Implementation Team in a DMAIC process of defining the problem, measuring the current state, analyzing the opportunities for improved flow and waste elimination, implementing the new MRO process, and creating Standard Work to control the new process. MainStream GS utilized Current and Future State Value Stream Maps (VSMs) to identify the project opportunities and define the desired end state.

Results:

Results included reducing:

  • Flow days by 53%
  • Work-in-process inventories by 90%
  • Floor Space by 20%
  • Distance traveled by 19%

*The total project savings were internally estimated at $1.9 million per year