From 7 Days to 24 Hours: How Curtiss-Wright Accelerated Production Orders with Xemelgo
Overview
Curtiss-Wright, a leader in industrial manufacturing with roots in aerospace innovation, implemented an RFID tracking solution to optimize its valve assembly operations. Faced with challenges tracking materials and managing work-in-process (WIP), the company partnered with Xemelgo, Arrowhead, and Zebra Technologies to deploy a comprehensive RFID system.
This solution provided real-time visibility, significantly reducing WIP inventory by 90% and shortening order processing times from seven days to 24 hours. The implementation not only streamlined operations and improved on-time delivery but also enhanced customer satisfaction. The project’s success showcases Curtiss-Wright's commitment to leveraging cutting-edge technology to maintain its legacy of operational excellence and customer satisfaction.
Challenges
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Limited visibility into WIP, making it difficult to manage and expedite aging or hot production orders
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Long production lead times due to a complex product mix with millions of part variations
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Reliance on institutional knowledge, intensified by retirement of experienced workers and new employees
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Low employee morale and increased frustrations due to non-value-added time searching for valves.
Solution
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Automated WIP Tracking: RFID labels attached to job travelers and RFID readers deployed sitewide automatically track production orders
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Proactive Operations Management: Real-time alerts and management map dashboard department health and performance for aging, delayed, and expedited orders to proactively identify and eliminate bottlenecks
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Data Integration: API capabilities seamlessly integrated RFID data with Curtiss-Wright’s Power BI tools, enhancing data-driven decision-making.
Results
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Boosted Operational Efficiency: Real-time visibility and management tools helped identify waste and remove bottlenecks
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85% Reduction in Lead Time: Order processing times dropped from 7 days to 24 hours, enhancing delivery speed and customer satisfaction
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90% Reduction in WIP Inventory: Improved material flow significantly reduced WIP inventory value.
Testimonial
"I have nothing but compliments for all parties involved. This has been the smoothest integration and implementation I have ever experienced — everything went smoothly."
— Lillie Walsh, Senior Manager of Supply Chain