At Project7 Consultancy, we have had the privilege of partnering with industry leaders to drive transformative change. One significant project involved a global leader in aircraft manufacturing. This reflection explores our journey with their US Final Assembly Line (FAL) in Alabama, highlighting the challenges faced, the solutions implemented, and the significant outcomes achieved.
At the Alabama facility, a new Final Assembly Line, was undergoing a critical transition from building two aircraft per month during its build phase to producing four aircraft per month as a fully operational assembly line.
This transition was compounded by the withdrawal of experienced European expats and the need to maintain production levels without significantly increasing the workforce.
The newly appointed General Manager recognised the need for a cultural shift towards a high-performance operating system to meet strategic goals of increasing US market growth and production volumes.
The key challenges at the Alabama facility included:
- Transitioning from experienced European employees to a new US workforce.
- Achieving a higher maturity level in their operating system, which was initially assessed at a D level with a target of A.
- Addressing employee engagement issues, as 60% of base-level employees rated leadership as either average or poor.
- Reduce the high levels of “travelled work,” where 40-50% of the planned workload was moved to subsequent workstations instead of being completed at one station.
These challenges highlighted the need for improved leadership, better material and workforce management, and the adoption of a systematic approach to assembly processes.
To address these challenges, Project7 was tasked with designing, implementing, and evaluating a world-class operating system across four levels of the Alabama organisation.
Our solution was based on the seven steps of the P7 Way, adapted to align with the company’s core principles:
- Strategy into Action
- Tiered Visual Performance Management (VPM)
- Short Interval Control & Performance Dialogues
- Performance Confirmation & Go Look See
- Setting Clear & Aligned Targets
- Problem-solving Level 1, Coaching for Success
- Problem-solving Level 2
- Talent Management and Leadership Development.
Additionally, we incorporated RACI Diagrams and ICOR Charts to clarify roles, tasks, and timelines, which facilitated significant breakthroughs in project success. By integrating these steps into the operating system, we aimed to create a high-performing culture that would enhance efficiency, reduce costs, and improve overall performance.
The implementation of the P7 Way and our tailored solutions led to substantial improvements at the US FAL:
- 40% reduction in travelled work, enabling the first-ever clean aircraft build within a workstation
- A significant positive shift in employee leadership survey results, moving from 60% negative ratings to 60% positive ratings
- Doubling production capacity from two to four aircraft per month, resulting in $2.4 billion in annual sales
- Increase in the operating system maturity assessment from D to B, with six categories moving to B and two to A.
These outcomes reflect the effectiveness of our approach in driving cultural and operational transformation. The success of this project not only met but exceeded the organisation’s strategic objectives, establishing a foundation for sustained high performance.
Reflecting on this project, several key lessons stand out:
- Implementing a world-class operating system requires a systematic approach that integrates leadership development, performance management, and continuous improvement.
- Building a high-performance culture involves engaging employees at all levels and fostering a sense of ownership and accountability.
- Adapting solutions to align with the client’s core principles and specific needs is critical for achieving desired outcomes.
- Ensuring thorough knowledge transfer and training for the local workforce is essential for sustaining improvements.
This project highlights the transformative impact that strategic interventions and a commitment to excellence can have on an organisation.
At Project7 Consultancy, we remain dedicated to helping our clients achieve their goals through targeted performance improvements and leadership development.
Please get in touch for more information on how Project7 Consultancy can help your organisation achieve similar results.
