Ducommun AeroStructures Realizes Cost Savings with Six-Sigma Implementation

Situation

To ensure sustainable profitable growth, subsequent to double digit sales growth and in the midst of challenging market conditions, the DAS NY, formerly Dynabil Industries, aerostructures manufacturing site required development of Lean Six Sigma tool kits throughout the organization.

Solution

In the Fall of 2008, 15 individuals navigated Lean training through the Center for Economic Growth. From January to May of 2009, 13 individuals completed, on behalf of CEG, the University at Buffalo Six Sigma Green Belt Training program. As a result, in 2009, 4 key projects were completed and are expected to yield on the order of $185,000 in cost savings in 2010.

One example of these projects is the Supplier Kanban Program. The problem statement: Details for assembly at OCS/OCD are late causing assemblies to ship late to the customer.

Using a SIPOC analysis followed by a fishbone diagram, the root cause was identified. Several additional opportunities were identified during the process. The Corrective Action was to define and employ a

Supplier Kanban Program.
A team, led by Supply Chain and Business Management, analyzed performance data and customer demand, identified key suppliers, and worked with them to develop the program. The program has been deployed with an aggressive schedule to grow the number of suppliers in the program.