Quality and efficiency are critical in the aerospace industry to ensure safety and competitiveness. However, production defects can significantly affect costs, delivery timelines, and customer satisfaction. Addressing these challenges requires a structured approach supported by the right tools.

A global aviation leader

This multinational conglomerate specializes in the production, services, and support of aircraft manufacturing and aerospace parts. With multiple facilities overseas, the company has established itself as one of the world’s leading manufacturers and a market leader in the aircraft segment with up to 130 seats. To meet high global demand, it operates numerous industrial sites, offices, and distribution centers for parts and services across several continents—from the Americas to Asia, including Europe.

How to reduce defects and costs in aerospace production

The aircraft structure assembly area of the aviation unit is responsible for assembling panels and airframe structures from different generations of aircraft. Over time, however, several quality issues were detected in the products delivered to customers, many of which were identified by the customers. These issues disrupted the aircraft assembly sequence, increasing lead times and significantly raising non-quality-related costs.

The company aimed to reduce the number of defective products in its assembly processes while lowering the non-quality costs (NQC) associated with these defects.

Actions implemented to improve aerospace production

To achieve the previously defined goals, the company adopted several initiatives and methodologies aimed at improving production processes, including:

• Implementation of Poka-Yoke at multiple levels (levels 1, 2, and 3), this error-proofing system was applied to prevent defects throughout the aerospace production process.
• Application of visual management in assembly operations, facilitating the identification and prevention of potential issues.

• Adjustment of tools and support equipment used in the assembly process, ensuring greater precision and production efficiency.
• Introduction of the briefing method in assembly routines, reinforcing communication and team alignment.

• Standardization of assembly processes, establishing stricter standards and procedures.

The impact of the implemented actions

Implementing the measures described above led to significant improvements in the quality and efficiency of assembly processes. The results presented refer to a five-month period, from the beginning of the project through its follow-up phase and indicate a continuing trend of positive impact over time.

Reduction in non-quality costs (NQC):

• Before the project: $33,000/month
• After the project: $3,800/month

This represents an 88% reduction, translating into monthly savings of $29,200.

Reduction in non-compliance events:

• Before the project: 77 events/month
• After the project: 40 events/month

There has been a 48% improvement in non-compliance, from 77 events to just 40, a reduction of 37 events per month.

As a result, implementing corrective and preventive actions led to significant gains in defect reduction, highlighting the positive impact of visual management, process standardization, and the application of Poka-Yoke. With continuous improvement now embedded in the organizational culture, these benefits are expected to expand over time, reinforcing the company’s position as a benchmark for excellence and quality in the aerospace industry.

We are committed to respecting our clients’ confidentiality. While we have altered or omitted their names, the results are genuine.