A turbine blade manufacturer in support of maintenance, repair, and overhaul of gas and steam turbines was experiencing factory lead times that exceeded customer requirements. This manufacturer supports turbine outage/turnaround repairs, which means that short and predictable manufacturing lead times are critical.
Flow Consulting worked with a cross-functional team to collect and analyze current-state data. We then facilitated a kaizen, with the goal of reducing total blade-kit cycle time by 50 percent.
The Kaizen focus used:
- One-piece flow
- Early and detailed planning
- And single-minute exchange of die concepts and techniques.
The factory lead time was reduced 48 percent, from 21 days to 11 days. Significantly shorter lead times using these new processes was achieved on the first set of turbine blades.