Resilience in Production

Faced with a significant ramp-up in production volumes of historic proportions, our experts were asked to investigate the robustness of a production system for a customer in the aerospace industry.

The aim of the project was to define measures to improve the resilience of the production system during the ramp-up of production volumes. To this end, our experts were tasked with analyzing the infrastructure and processes of component production with regard to potential disruptions and their robustness.

In the first step, our experts used a value stream analysis to review the production processes and their resources in order to identify challenges and derive potential risks. In order to prioritize these potential weak points within the production system, the second step involved simulating the behaviour of the production system based on scenarios. In a third step, our experts were then able to derive optimization potential and recommendations for action for particularly critical processes, for example by avoiding unplanned interruptions in the production process to improve the robustness of the production system during the production ramp-up.

Thanks to our analyses, the client has gained an in-depth understanding of the value chain and its interactions with internal (production network) and external (supplier) interfaces. Critical risk drivers were identified for the planned ramp-up of production volumes and adequate recommendations for dealing with them were made. Finally, a structured roadmap for implementing the measures was provided, which the plant under investigation can use to increase its resilience and reduce any contractual penalties due to delayed delivery of products to customers.