Develop Consulting are improvement experts working with aerospace manufacturers and their supply chains to transform operational performance by identifying issues and improving efficiency, productivity, quality and profitability across all areas of the sector.
From aircraft and engine OEMs to their supply chains, from spacecraft production to component manufacturing, we work hand-in-hand with our clients to deliver increased efficiency, productivity, quality and profitability.
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The UK aerospace sector is experiencing significant growth. With major defence programmes, commercial aircraft production ramp-ups and emerging space ventures, manufacturers are well positioned to deliver complex, safety-critical products whilst strengthening quality performance and cost competitiveness.
Whether producing engines, airframes, landing gear, avionics or interior components, aerospace manufacturers face unique operational challenges. From long TAKT builds on major assemblies to higher-volume component production, each requires precision planning and flawless execution.
Component and sub-assembly production demands management of specialist processes including composite layup, precision machining, heat treatment, surface finishing and NDT, each with exacting tolerances and full traceability requirements.
Late-stage quality escapes prove extremely costly when products are high-value and highly regulated. AS9100 compliance, airworthiness certification and customer quality requirements create layers of documentation and oversight. Design changes during production, concession management and non-conformance investigation must be handled effectively without creating bottlenecks. Specialist jigs, fixtures and skilled resources become critical constraints whilst customer delivery expectations intensify.
Many aerospace manufacturers have significant opportunities to improve production planning across extended timelines, strengthening coordination of multiple dependencies and specialist resources. Better flow and performance management can unlock throughput where capacity constraints appear to exist. Improved alignment across supply chains, including machining, composite manufacture, systems integration and specialist finishing, can reduce lead times and delivery uncertainty. As programmes transition from development to rate production, tighter control of First Article Inspection, configuration management and engineering changes, combined with targeted development of operational leadership and technical capability, enables more predictable delivery.
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We understand change can be difficult in highly regulated environments where compliance cannot be compromised. It’s not always clear where to start or what to prioritise when facing competing demands of cost, quality, delivery and regulatory requirements.
Develop Consulting works hands-on with your team to identify and make the changes needed to stretch your resources further, put robust planning in place and be able to quickly action improvement for real, tangible and sustainable change. We work within your quality management system, supporting rather than disrupting your certification and compliance requirements.
With much of our team having first-hand experience of Toyota motor manufacturing in the UK and Japan, our preferred delivery model is based on Lean methodology, which we have adapted over many years to help organisations across multiple sectors set up processes and train people to be more productive, effective and efficient.
Our aerospace team brings direct industry experience. Team members have worked at Rolls-Royce on engine component production systems, at Airbus on manufacturing process improvements, and throughout the aerospace supply chain.
The aerospace sector, with its stringent quality requirements, long build cycles and safety-critical operations, benefits significantly from structured Lean approaches adapted for AS9100 compliance and airworthiness certification. This methodology enhances planning accuracy, coordinates activities across complex operations and supply chains to reduce rework, improves right-first-time performance and supports on-time delivery across all areas of your organisation. Crucially for aerospace, it does so whilst maintaining full regulatory compliance and supporting, rather than conflicting with, quality management system requirements.
Develop Consulting will work with your team to transfer our knowledge, ensuring improvements are sustainable and your organisation builds long-term capability within your processes and people.
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