Mitigating The Risk Of A New Workforce By Reducing Rework And Rightsizing On Hand Inventory

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Executive Summary

Dramatically increasing the hourly workforce at a rapid pace to support accelerated product demand in an aircraft manufacturing facility in a short amount of time resulted in: increased rework, and increased part damage during assembly. The majority of rework results from simple workmanship mistakes from the new workforce. The approach used in this paper to combat the increase in rework involves the design and implementation of a feedback loop on the shop floor of a leading aircraft manufacturer. The loop consists of providing each worker with a list of their discrepant work from the day before and the opportunity for them to perform their own rework.

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