Todd Hanlin

With over 25 years of experience as a Senior Aerospace Quality leader to Tier 1 aircraft manufacturers, Todd Hanlin has been an integral part of Competitive Business Solutions (CBS) for years, bringing a passion for Continuous Improvement to his role as Principal Consultant. Starting his journey in the aerospace industry, Todd has been instrumental in…

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Reducing Product Reworks, Defects and Costs

CLIENT INDUSTRY: Tier 2 Aerospace and Defense Company
SOLUTION: Operational Excellence, Supply Chain

A global Tier 2 wings supplier with revenues of more than $3 billion was experiencing process issues that compromised its ability to meet customer demands for delivery, cost and quality. CBS helped the client achieve significant reductions in unit labor hours, defect rates and product rework while facilitating a return to on-time deliveries.

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A Return to Profitability: Improving the Supply Chain Strategy

CLIENT INDUSTRY:Specialties Chemical Manufacturer
SOLUTION: Operational Excellence

A Fortune 500 company required assistance in improving the profitability of a recently acquired chemical company. Previously family-owned and marginally successful in its region, the company lacked a supply chain strategy and standard work in their operations. CBS returned the company to profitability through product rationalization, improved inventory practices and targeted operational improvements.

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Improving Productivity and Decreasing Costs

CLIENT INDUSTRY: Packaging Manufacturer
SOLUTION: Operational Excellence, Supply Chain

A labeling manufacturer lacked the capacity to meet its customers’ volume and mix requirements, resulting in costly additional shifts, selective outsourcing and loss of large client orders. CBS led a Kaizen event to analyze and improve the process, which reduced the average changeover by 60% and helped decrease the need for temporary workers and weekend shifts.

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Timing is Everything: Meeting Demand for Critical Product Lines

CLIENT INDUSTRY: Aerospace and Defense Company
SOLUTION: Operational Excellence

A designer and manufacturer of high-tech military products, this company was unable to meet customer demands, resulting in customer dissatisfaction and the potential for contractual penalties. CBS helped the company develop capacity tools for critical product lines, eliminated non-value-added activities and implemented a takt-based system that doubled shop capacity and reduced product lead time from 50 days to 13 days.

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Training the Workforce for Improved Performance

CLIENT INDUSTRY: Aerospace and Defense Company
SOLUTION: Operational Excellence, Leadership and Change Management

A manufacturer of wings and supporting aerostructures was experiencing high rates of employee attrition, which impacted delivery deadlines and revenue goals while compromising important customer relationships. An intensive CBS engagement helped the supplier implement a robust workforce training program, significantly reduce product defects and rapidly improve on-time delivery rates.

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