Customer and Supplier Integration Across the Supply Chain

Lean Aircraft Initiative Implementation Workshop repor

CASE STUDY: Textron Systems

For over five decades, Textron Systems has been an important contributor to the U.S. defense aerospace business. Its breakthroughs in thermal protection materials enabled NASA Apollo command modules and Air Force intercontinental missiles to successfully re-enter the earth’s atmosphere. High strength, lightweight boron composites from Textron Systems help carry the primary structural load in the Space Shuttle orbiter and today’s aircraft carriers rely on Textron’s automated landing systems. Textron highlights smart systems, including smart air and ground munitions, as its unique value add in the 21st Century global marketplace -- products that can rapidly acquire, analyze and act on real-time data inputs. The constant adaptation of its product line and business strategy is a defining feature of Textron Systems as a business. This is a significant accomplishment for the business, but a constant challenge when it comes to work organization and skill development. Textron Systems is based in Wilmington, Massachusetts, with additional facilities in three other locations. This case study is focused on the Wilmington operations

Fostering Continuous Improvement in a Changing Business Context

Case studyFor over five decades, Textron Systems has been an important contributor to the U.S. defense aerospace business. Its breakthroughs in thermal protection materials enabled NASA Apollo command modules and Air Force intercontinental missiles to successfully re-enter the earth's atmosphere. High strength, lightweight boron composites from Textron Systems help carry the primary structural load in the Space Shuttle orbiter and today's aircraft carriers rely on Textron's automated landing systems. Textron highlights smart systems, including smart air and ground munitions, as its unique value add in the 21st Century global marketplace -- products that can rapidly acquire, analyze and act on real-time data inputs. For most of its products, such as the smart munitions, Textron Systems is a prime contractor with the U.S. government, while it also serves as a first-tier supplier for other technologies, such as boron composite components. The uncertainties associated with each role -- contractor and supplier -- are different and both are part of the Textron story. The constant adaptation of its product line and business strategy is a defining feature of Textron Systems as a business. This is a significant accomplishment for the business, but a constant challenge when it comes to work organization and skill development. Beginning with quality principles in the 1980s and extending into lean principles in the 1990s, workplace change initiatives have been seen by Textron Systems as key to business success. The current initiative, which is entitled "10X" targets not just incremental gains, but performance gains of an order of magnitude or gains that are ten times current performance. Concurrently, Textron has long invested in employee training and development, another significant part of this case. Textron Systems is part of the larger Textron Corporation, which includes the Textron Automotive Corporation, Cessna, Bell Helicopters and other businesses -- all of which have a high degree of autonomy. Textron Systems is based in Wilmington, Massachusetts, with additional facilities in three other locations. This case study is focused on the Wilmington operations, which are non-union. As a 1,400-person facility, the spirit of the operation is reflected in an internal presentation slide that features a picture of a huge gorilla and the statement, "We're competing with meg

CASE STUDY: Boeing Commercial Airplane Group Wichita Division (Boeing Co.)

Activity Based Costing and Management (ABCM) is one of many new financial and accounting tools aimed at providing more complete, better-aligned data on economic performance. It is important to explore early experiences with this concept since it represents a new set of “rules” that can have implications for all stakeholders in an aerospace enterprise. ABCM is of particular interest with respect to lean practices and principles since it links the cost of production or services to the relevant support activities, which is helpful in targeting continuous improvement efforts. Companies who are focusing resources on organizational learning initiatives will also find that ABCM processes add value to these efforts. This case study hopes to deepen understanding of ABCM principles by looking beyond the survey data and tracing early experience in an aerospace setting. Note that these are just pilot demonstration initiatives and do not represent full-scale implementation. In presenting this study, we are not advocating for or against this particular approach to financial accounting – just seeking to better understand its implications

The Impact of Instability on Complex Social and Technical Systems

Instability is a pervasive phenomenon that has deep implications for virtually all complex social and technical systems. In engineering, the identification and mitigation of various types of technical instabilities is a well developed practice. This is a key focus, for example, of engineers concerned about the prevention of potentially destabilizing vibration in the frame of an aircraft or the mitigation of sources of technical instability in the operation of a nuclear reactor. However, the nature of instability in complex social and technical systems is relatively unstudied and not well understood. This is unfortunate because instability can have profound effects on the performance of those systems as well as their ability to improve their performance over time. In this paper, we present a conceptual framework for understanding instability in sociotechnical systems. To illustrate what we mean by instability in the context of complex engineering systems, we will draw on data from the aerospace industry. In particular, we use two data sets, to trace the impacts of various sources of instability. One data set centers on instability and its impact on aerospace programs, while the other centers on instability and its impact on aerospace production and design facilities

Growing the Lean Community

Creativity and Adult Learning PrinciplesLabor Aerospace Research Agenda and Engineering Systems Learning Cente

Implementation Workshop Highlights: Customer and Supplier Integration Across the Supply Chain

Lean Aerospace Initiative Plenary Workshop presentatio

Lean Transformation in the U.S. Aerospace Industry: Appreciating Interdependent Social and Technical Systems

Lean practices and principles build on a half-century of successive initiatives aimed at transforming social and technical systems in organizations. While they are send as central to the revitalization of the U.S. aerospace industry, there is great variation in the degree to which lean initiatives emphasize just technical/manufacturing systems versus additional social and enterprise dimensions. Based on a national random sample survey of 362 U.S. aerospace facilities, this paper examines factors that account for the incidence of lean practices and the impact on outcomes relevant to key stakeholders. While structural factors such as industry sector, facility size and others have limited explanatory power, two process factors – organizational learning and the value placed on intellectual capital – do account for the increased presence of lean practices. In examining employment outcomes, facilities higher just on the technical/manufacturing aspects of lean have a significant and negative impact on job growth, while facilities higher around the social systems associated with lean have significant and positive employment growth. This finding is consistent with the views of critics of the more narrow technical, manufacturing-oriented approaches to lean as a threat to employment and it validate proponents of a broader value-creating approach to lean as a way of growing the enterprise. Enterprise dimensions of lean (including both social and technical aspects of lean) have a positive impact on productivity. Examining outcomes relevant to multiple stakeholders and various factor inputs produces a more complete understanding of the limitations and potential for lean transformation in the aerospace industr

Implementation IPT

Lean Aircraft Initiative Plenary Workshop presentatio