Innovation Success Story

Less Means More for Ducommun Technologies

Phoenix-based Ducommun Technologies (DTI) is the country’s second largest supplier of electromechanical illuminated push button switches for the aerospace industry. It also is a major supplier of microwave switches and components used for the wireless communications and aerospace industries, as well as a leading manufacturer of products which provide sub-system integration for electronics, defense and commercial aviation industries. A third tier supplier to aerospace companies, DTI sought to improve its production efficiency in order to meet the growing demands of its clients.

Partnering with Time Wise Management Systems and the Arizona Manufacturing Extension Partnership (Arizona MEP), DTI participated in a supplier integration process improvement program.

The project team began by conducting a technology road map assessment of the facility’s processes, outlining observations and suggestions. The team determined that DTI qualified for an H-1B grant funded by the U.S. Department of Labor and administered by the Northern Arizona Council of Governments. Utilizing the grant, DTI engaged the project team to facilitate a series of lean training and simulations to help the company learn to identify and eliminate waste and inefficiencies that inhibited productivity.

Although DTI’s radar rack manufacturing process had been done in a general assembly area, Kaizen events helped transform the area into a cell with five work stations where parts now flow from station to station. Changes to the work stations mean that tools and materials are at the employees’ fingertips. As employees now note, everything has become more visual. Work instructions for each process are now available at each station via computer, and employees can be cross trained.

These simple changes made a significant difference in how efficiently the work was being done. For example, on a project for Boeing, Ducommun had been producing three units of the radar rack per month with a lead time of more than 50 days. Now they are producing six units in about half the time. Their hours per assembly were also dramatically reduced by 34 percent, which represents a sizeable cost reduction.