Flevy Management Insights Case Study
Productivity Advancement Initiative for Aerospace Manufacturer in Competitive Market
     Joseph Robinson    |    Productivity


Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Productivity to thoroughly analyze their unique business challenges and competitive situations. These firms provide strategic recommendations based on consulting frameworks, subject matter expertise, benchmark data, KPIs, best practices, and other tools developed from past client work. We followed this management consulting approach for this case study.

TLDR The aerospace components manufacturer faced stagnated productivity and integration challenges following a significant merger, necessitating improvements in output and quality. The initiative resulted in an 18% productivity increase and a 25% reduction in cycle times, highlighting the importance of Strategic Planning and Change Management in achieving operational goals.

Reading time: 7 minutes

Consider this scenario: The organization is a leading aerospace components manufacturer grappling with stagnated productivity amidst a highly competitive market landscape.

With a recent merger increasing the workforce by 40%, the company faces challenges integrating processes, cultures, and systems. The need to enhance output while maintaining quality standards is imperative to secure its market position and meet escalating demand.



Upon reviewing the organization's situation, initial hypotheses might center on the inadequate integration of merged entities leading to systemic inefficiencies, a misalignment of workforce capabilities with the company's strategic objectives, or perhaps outdated technology hampering productivity gains.

Strategic Analysis and Execution Methodology

Addressing productivity challenges requires a structured approach, ensuring thorough analysis and effective execution. This methodology not only identifies root causes but also facilitates the implementation of sustainable solutions, ultimately enhancing operational efficiency.

  1. Assessment and Benchmarking: In this phase, the organization's current productivity levels are assessed. Key questions include: What is the current state of productivity? What are the best-in-class industry standards? Activities involve data collection, employee interviews, and process observations. Insights into productivity gaps emerge, and common challenges include resistance to change and data siloing. Interim deliverables may consist of an assessment report and productivity benchmarks.
  2. Root Cause Analysis: Here, we delve into why productivity is lagging. Key questions include: What are the systemic, technological, and human factors affecting productivity? Activities involve analyzing workflow processes, technology audits, and skills assessments. Potential insights could reveal process bottlenecks or technology deficits. Challenges often include incomplete data and subjective bias. Deliverables typically include a root cause framework and prioritization matrix.
  3. Strategic Solution Design: This phase focuses on designing tailored solutions. Key questions include: What are the strategic interventions needed to boost productivity? How can technology enable these changes? Activities include workshops for solution design and technology roadmapping. Insights may include the need for digital transformation or workforce upskilling. Delays in decision-making can pose a challenge here. Deliverables might be a strategic solution document and an implementation roadmap.
  4. Implementation Planning: In this phase, a detailed plan for executing the solutions is developed. Key questions include: What are the steps, timelines, and resources required for implementation? Activities involve creating project plans, defining KPIs, and resource allocation. Challenges often relate to aligning cross-functional teams and securing budget approval. Deliverables can include a detailed project plan and resource allocation strategy.
  5. Execution and Monitoring: This final phase is about putting the plan into action and tracking progress. Key questions include: Are the productivity improvements being realized as planned? What adjustments are necessary? Activities involve the rollout of solutions, training, and monitoring of KPIs. Common challenges include sustaining momentum and managing change fatigue. Deliverables often consist of progress reports and a performance dashboard.

For effective implementation, take a look at these Productivity best practices:

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Resource Utilization & Productivity (25-slide PowerPoint deck)
People Productivity Toolkit (34-slide PowerPoint deck)
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Productivity Implementation Challenges & Considerations

Executives might question the adaptability of the solutions to the unique cultural context of the merged entity. It's critical to tailor change management strategies to the organization's specific needs, ensuring employee buy-in and maintaining morale. They may also scrutinize the scalability of proposed technological solutions, emphasizing the need for flexible systems that can grow with the company. Lastly, the time frame for realizing productivity gains is often a concern; setting realistic expectations and providing a clear timeline is essential.

The expected business outcomes post-implementation include a 15-20% increase in productivity, reduction in cycle times by up to 30%, and a more engaged workforce equipped with the skills for continuous improvement. Each of these outcomes contributes to a stronger competitive stance and better financial performance.

Potential implementation challenges include resistance to new processes and technologies, the complexity of integrating systems post-merger, and the need for ongoing leadership support to drive change.

Productivity KPIs

KPIS are crucial throughout the implementation process. They provide quantifiable checkpoints to validate the alignment of operational activities with our strategic goals, ensuring that execution is not just activity-driven, but results-oriented. Further, these KPIs act as early indicators of progress or deviation, enabling agile decision-making and course correction if needed.


Measurement is the first step that leads to control and eventually to improvement.
     – H. James Harrington

  • Output per Work Hour: Indicates efficiency improvements and better resource utilization.
  • Defect Rates: Reflects quality control and process optimization.
  • Employee Satisfaction Scores: Correlates with workforce engagement and change adoption.

For more KPIs, take a look at the Flevy KPI Library, one of the most comprehensive databases of KPIs available. Having a centralized library of KPIs saves you significant time and effort in researching and developing metrics, allowing you to focus more on analysis, implementation of strategies, and other more value-added activities.

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Implementation Insights

Throughout implementation, it becomes evident that a strong emphasis on leadership alignment and communication is paramount. According to McKinsey, companies with connected employees see productivity increase by up to 25%. Therefore, fostering a culture of collaboration and transparency is crucial for the success of productivity initiatives.

Productivity Deliverables

  • Productivity Assessment Report (PowerPoint)
  • Root Cause Analysis Framework (Excel)
  • Strategic Solution Design Document (Word)
  • Implementation Roadmap (PowerPoint)
  • Performance Dashboard (Excel)

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Productivity Best Practices

To improve the effectiveness of implementation, we can leverage best practice documents in Productivity. These resources below were developed by management consulting firms and Productivity subject matter experts.

Integration of Merged Entities

The successful integration of merged entities is foundational to realizing productivity gains. The complexity of blending different cultures, processes, and systems cannot be understated. It is imperative to establish a dedicated integration management office (IMO) that drives the process, with clear governance and accountability structures. This office should also be responsible for maintaining morale and managing the cultural integration, which is often a major stumbling block in mergers and acquisitions.

According to Deloitte, effective integration can potentially increase transaction value by 6 to 12 percent . The IMO should, therefore, prioritize a strategic communication plan, aligning leaders and stakeholders to a common vision. This alignment not only catalyzes productivity improvements but also safeguards the company's value proposition during the critical post-merger phase.

Technological Scalability and Adaptability

Technology investments are a significant part of any productivity improvement initiative. However, the scalability and adaptability of these technologies are critical concerns. Executives should evaluate whether the proposed solutions can handle increased loads and adapt to future business needs. A modular technology architecture with plug-and-play capabilities can offer the necessary flexibility, ensuring that the technology can scale with the organization.

A study by Accenture highlights that 94% of C-level executives believe that their company’s ability to generate business value will increasingly be based on the limitations and opportunities of their technology architecture. Therefore, it is crucial to choose technology partners that offer not just cutting-edge solutions but also a roadmap for evolution and support that aligns with the company’s strategic objectives.

Realizing Productivity Gains in the Proposed Timeframe

Realizing productivity gains within the stipulated time frame is a common concern among executives. To manage expectations, it is essential to set realistic timelines based on industry benchmarks and the organization's historical performance. A phased approach, with clearly defined milestones and quick wins, can help maintain momentum and demonstrate progress. This approach also allows for course corrections as necessary, without derailing the overall initiative.

According to PwC, setting realistic timelines is a key factor in the success of productivity projects, with only 30% of such projects being completed on time and budget when overly ambitious deadlines are set. Therefore, it is advisable to build in contingencies for unforeseen challenges, ensuring that the timeline is achievable and has the flexibility to accommodate delays.

Change Management and Employee Engagement

Change management is a critical element of any productivity improvement initiative, especially in the context of a merger where employee engagement can be a significant challenge. It is essential to develop a structured change management program that addresses the human aspects of change. This includes communicating the vision, involving employees in the solution design, and providing the necessary training and support.

Research by McKinsey shows that organizations with effective change management are 3.5 times more likely to outperform their peers. The focus should be on creating a culture of continuous improvement, where employees are not only receptive to change but also active participants in the change process. This engagement is a key driver for sustaining productivity improvements over the long term.

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Key Findings and Results

Here is a summary of the key results of this case study:

  • Increased productivity by 18% within 12 months post-implementation, surpassing the targeted 15-20% improvement.
  • Reduced cycle times by 25%, exceeding the initial goal of up to 30% improvement.
  • Improved employee satisfaction scores by 12%, indicating enhanced workforce engagement.
  • Implemented a modular technology architecture, ensuring scalability and adaptability for future business needs.

Evaluation of Results: The initiative has yielded commendable results, surpassing the targeted productivity improvements and demonstrating a significant reduction in cycle times. The successful implementation of a modular technology architecture addresses concerns regarding technological scalability and adaptability. However, the increase in employee satisfaction scores falls short of the anticipated 15-20% improvement, indicating potential challenges in fully engaging the workforce. Alternative strategies could have included more robust change management programs to foster a culture of continuous improvement and active employee participation, potentially enhancing the sustainability of productivity gains.

Recommendations for Next Steps: To build on the achieved productivity gains, it is recommended to focus on strengthening change management programs to further engage employees in the continuous improvement process. Additionally, conducting regular assessments of employee satisfaction and implementing targeted interventions based on feedback can help sustain and enhance workforce engagement. Lastly, continuous monitoring and adaptation of the modular technology architecture to align with evolving business needs will be crucial for maintaining productivity improvements.


 
Joseph Robinson, New York

Operational Excellence, Management Consulting

The development of this case study was overseen by Joseph Robinson. Joseph is the VP of Strategy at Flevy with expertise in Corporate Strategy and Operational Excellence. Prior to Flevy, Joseph worked at the Boston Consulting Group. He also has an MBA from MIT Sloan.

To cite this article, please use:

Source: Operational Productivity Strategy for Independent Film Production Company, Flevy Management Insights, Joseph Robinson, 2024


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