Engineering productivity

A leading aircraft manufacturer was sequencing the development and launch of a number of new aircraft derivatives at the same time. As they were launching a new aircraft type, two other models were in the middle or starting phase of their development. Additionally, new models, with entirely different cabin sections and on-board systems were also scheduled to be launched in the same timeframe.

Challenge
The manufacturer faced numerous challenges in achieving successful launch of these aircraft types. One of the most critical was to effectively manage engineering resources to ensure their highest efficiency levels as these were stretched to meet the competing demands of these individualized launches. Failure to optimize engineering productivity would result in delays, cost-overruns and even more pressure on scarce resources.

Approach
Working with the client’s engineering team, A.T. Kearney was able to devise new processes and management systems to address the three key areas needed to ensure smooth, on-time launches:

• Management of information flow and interactions between engineering and customers, especially design definitions
• Control of engineering deliverables across the engineering process, from predesign, through assembly drawings, and across the different functional disciplines in aircraft development
• Support to, and integration with, manufacturing in building the aircraft

Results
This work helped the successful launch of the new aircraft and has been applied to other aircraft programs. Broader impacts have included

• New process for Engineering Upstream Management, which spans from contract signing to customer definition
• Quality-gate framework
• Monitoring systems for engineering delivery
• Redesigned interface between engineering and manufacturing