Gas Turbine Casing Manufacturing & Repair Plant (Global 500 Division)
Client Challenge
Alstom needed to replicate the successful Turbine Repair transformation at a separate Gas Turbine Casing plant — different product line, workforce, and operational cadence
The plant was unprofitable with manufacturing cycle times exceeding 8 months
A pre-sale transformation: the plant was being positioned for acquisition
Client Solution
Model Transfer: Assessed transferability of the proven operating model and tailored the future-state ETC framework for casing manufacturing
Redesign: Rebuilt organizational structure, process workflows, roles, and technology stack with a 5+ person matrix team
Lean Discipline: Gemba Walks and Complexity Lean Value Stream Mapping drove the redesign
ERP: Implemented the JDE configuration supporting the new processes
Client Impact Results
Cycle Times: Reduced from 8+ months to under 3 months
Profitability: Unprofitable plant became a positive contributor
Transferability: Operating model validated across a second manufacturing context in 6 months
Outcome: Plant subsequently acquired by GE
Client Technologies
JD Edwards ERP
ETC process methodology
Complexity Lean Value Stream Mapping
Gemba Walks
Organizational design
Matrix team management
