Faced with significant challenges in managing their supply chain and inventory, Qarbon Aerospace, a leading manufacturer of advanced composite components and assemblies, embarked on a mission to enhance operational efficiency. Known for its crucial role in both commercial and military aviation sectors, the company operates from a substantial U.S.-based footprint of over 1,650,000 square feet of state-of-the-art facilities. Despite their innovative and complex product solutions, Qarbon Aerospace needed to address numerous inefficiencies that plagued their supply chain. The implementation of LeanDNA’s supply chain execution solution marked a turning point, resulting in a remarkable 44% improvement in supplier delivery performance. This article delves deep into the challenges faced, the strategic solutions adopted, and the impressive outcomes achieved by Qarbon Aerospace.
Challenges Faced by Qarbon Aerospace
Qarbon Aerospace encountered numerous hurdles in their inventory management processes, which significantly hindered their operational efficiency. Common issues included discrepancies in stock levels, inaccuracies in demand forecasting, and disruptions within the supply chain. These challenges often led to shipment delays and misaligned priorities, further compounding the existing problems. The most pronounced issue, however, was the inability to gather and analyze essential data and analytics promptly, making it difficult for management to make informed decisions regarding the supply chain.
Previous attempts to resolve these issues involved several strategies, such as inventory reduction projects, outsourcing to third-party machines, and program readiness reviews. Unfortunately, these efforts were mostly managed outside their ERP system using manual tools like Excel. This approach resulted in delayed reporting, increased human errors, and a lack of accountability. Consequently, these methods achieved limited success, and Qarbon Aerospace needed a more robust solution to address the complex nature of their supply chain management woes.
Implementation of LeanDNA
In a bid to overcome the multitude of challenges they faced, Qarbon Aerospace decided to implement LeanDNA, a comprehensive supply chain execution solution designed to optimize various supply chain processes. LeanDNA offers a suite of powerful tools that facilitate better-structured processes and create a resilient supply chain infrastructure. One of the key factors that influenced Qarbon Aerospace’s decision to choose LeanDNA was the platform’s exceptional customer service and willingness to listen and adapt to user feedback.
The implementation process involved seamlessly integrating LeanDNA into Qarbon Aerospace’s existing systems and training the staff to effectively use the new tools. The transition was notably smooth, thanks to LeanDNA’s user-friendly interface and comprehensive support. The platform provided enhanced procurement visibility and forecasting, streamlining the reporting process for daily shortages and past dues. This increased visibility allowed the team to better manage their supply chain, significantly reducing inefficiencies and improving overall operational performance.
Results Across the Organization
The adoption of LeanDNA brought substantial improvements across Qarbon Aerospace, reflecting a marked enhancement in various aspects of their operations. Within just six months, the supplier delivery scores increased by an impressive 44%, demonstrating a profound improvement in supplier reliability. Furthermore, the incidence of purchase orders placed outside of lead time saw a significant decrease, indicating improved planning and execution within the organization.
Enhanced visibility, afforded to various teams within the organization, played a crucial role in better reviewing shortages and managing past-due purchase requirements on a daily basis. This newfound transparency saved significant time and ensured the maintenance of organized and accessible reports. For instance, Rhonda Knight, a buyer at Qarbon’s Milledgeville site, highlighted how LeanDNA streamlined daily operations by making reports more manageable. Additionally, Delivery Assurance expert Wess Hart emphasized that LeanDNA facilitated the identification of problem parts and future deliveries, ensuring manufacturing status aligned with on-time delivery expectations. The improvements achieved through LeanDNA have laid the foundation for a more efficient and reliable supply chain process.
Looking Ahead: Ambitious Goals and Continuous Improvement
Building on the successes achieved with LeanDNA, Qarbon Aerospace has set ambitious goals for the future, aimed at further enhancing their operational performance. One of their key objectives is to develop standardized dashboards to improve team accountability and streamline communication across different departments. By creating a more cohesive and transparent workflow, the company aims to ensure every team member is aligned with their goals and responsibilities.
Additionally, Qarbon Aerospace plans to onboard vendors to Supplier Connect, a platform designed to bolster communication and drive on-time delivery performance to reach an ambitious 95% target. This initiative is part of a broader strategy to foster stronger relationships with suppliers and ensure better alignment with the company’s standards and expectations. To achieve these goals, Qarbon Aerospace intends to develop internal LeanDNA subject matter experts (SMEs) and customize training courses to better align with specific roles and responsibilities. Supplier training is also on the agenda, ensuring that all suppliers are equipped with the knowledge and tools needed to meet Qarbon’s high standards.
Reflecting on the Impact of Modern SaaS Tools
To overcome a myriad of challenges, Qarbon Aerospace opted for LeanDNA, a robust supply chain execution solution designed to enhance various supply chain processes. LeanDNA provides an array of powerful tools that streamline processes and establish a resilient supply chain framework. A crucial factor in Qarbon Aerospace’s decision to adopt LeanDNA was the platform’s outstanding customer service and its responsiveness to user feedback.
Integrating LeanDNA into Qarbon Aerospace’s existing systems and training staff to use the new tools was a smooth process due to LeanDNA’s intuitive interface and solid support. This transition enhanced procurement visibility and forecasting and streamlined daily shortage and past due reporting. The improved visibility enabled the team to manage their supply chain more effectively, significantly reducing inefficiencies and boosting overall operational performance. By implementing LeanDNA, Qarbon Aerospace was able to create a more structured process environment and improve their supply chain resilience, leading to better results and operational excellence.