Implementation of lean processes at a high-mix low-volume aerospace manufacturing facility in France

Abstract

The theories of the Toyota Production System have been operational touchstones now for over twenty years in North America and Western Europe. In spite of this many companies, particularly those in high-mix low-volume manufacturing, continue to struggle with their implementation. The goal of this thesis is to openly examine the fit of the Lean tradition with the realities of complex high-mix low-volume processes and pave the way for improvements. This thesis explores the implementation of Lean processes at Jodd-Thonson's aerospace manufacturing facility, Daugy-Naudier, in France. The work is divided into two parts: 1. Implementation of Lean manufacturing principles in the Actuator assembly and machining department and benchmarking of challenges with other LFM Lean projects at other high-mix, low-volume manufacturers, 2. Implementation of a process to evaluate the cost and return on engineering changes as well as improvement to the change management process. Through the analysis of case studies, this thesis questions the relevance of some widely accepted Lean tools in the context of complex high-mix low-volume environments. I develop a set of hypotheses about risk factors and solutions particular to high-mix-low-volume Lean implementations. The combination of strategic and tactical projects examined in this thesis shows that implementing Lean in high-mix low-volume is necessarily an enterprise-wide process. Its success depends on developing a Lean culture that can successfully leverage distributed, tacit knowledge about complex products and processes.