Weber Aircraft LLC

GAINESVILLE, TEXAS – Weber Aircraft LLC, a leading manufacturer of commercial aircraft seats, is at the forefront of the industry with new advances in lean manufacturing.

Hold On To Your Seat: A Company Transformed by Lean Manufacturing

Weber Aircraft LLC recently incorporated lean manufacturing systems into all aspects of its manufacturing operations to reduce production times and increase overall efficiency. Lean manufacturing, a process originally developed by the automotive industry, utilizes principles such as a one-piece flow system and reduced inventory to maximize product output.

Weber Aircraft LLC began streamlining its operations with lean manufacturing protocols in 2001. Within just six months, the company had dramatically restructured its operations, resulting in significant savings in time and money. In one example, the company has reduced by 87% the average time it takes to begin manufacturing a new order.

Positioned to Take the Lead

“Weber Aircraft is positioning itself to become an industry leader in lean manufacturing advances,” said Michel Labarre, President of Weber Aircraft LLC. “Our rate of advancement has been significantly higher than many other companies.” As an example, Labarre cited a new collaborative effort with Boeing to improve the seat installation process that will dramatically improve efficiency.

Tim Daniel, the Director of Program Management at Weber Aircraft LLC, is responsible for implementing the company’s lean manufacturing initiatives. Daniel worked in the automotive industry at a time when they were pioneering many new lean manufacturing processes. He spent time both in the U.S. and Mexico incorporating lean manufacturing processes in automotive plants, and training employees on the principles of the new process. Daniel has over 25 years of management experience, including 15 years in the aviation and aerospace industries.

Developing lean manufacturing at Weber Aircraft was an innovative process from the beginning, said Daniel.

First, the company consolidated all of its manufacturing and engineering facilities into one central location in Gainesville, Texas, to reduce the logistical demands and communication constraints faced by manufacturers with widespread operations. With this strategy, Weber Aircraft has created a fast-track production schedule that minimizes lead time between finalizing a contract and beginning the manufacturing process.

Another difference in Weber Aircraft’s development of lean manufacturing was the extent to which they involved all employees in the decision-making process. To achieve real top-to-bottom improvements, the company held more than 110 workshops in just one year. The company workshops involved both management and non-management employees in discovering new ways to improve efficiency.

A Case History: Weber’s Lean Manufacturing In Action

One example that demonstrates the benefits of Weber Aircraft LLC’s lean manufacturing system is the recently streamlined process for producing tourist class welded saddle legs. The company held a four-day workshop for employees involved in the process in order to develop new goals for improving this process.

At the end of the workshop, Weber Aircraft LLC combined the recommendations of managers and the suggestions of the crew to devise an altogether new strategy for manufacturing welded saddles. These recommendations included better coordination, replacing duplicative tasks, reorganizing the assembly line, and using a one-piece flow system.

A New Collaborative Effort With Boeing

Weber Aircraft’s success with lean manufacturing recently gained the attention of Boeing. Already a preferred supplier of Boeing, Weber Aircraft LLC began a new collaborative effort with the U.S. aircraft manufacturer earlier this year to integrate lean manufacturing principles into the aircraft seat installation process. The new program, being developed jointly between Weber Aircraft LLC and Boeing, enables aircraft seats to be installed directly “from dock to plane.” Under the old system, installation was a more labor-intensive process that involved the temporary storage of seating at a warehouse and additional preparations before installation could take place.

About Weber Aircraft LLC

Weber Aircraft LLC, a subsidiary of Zodiac, is one of the world’s top manufacturers of commercial aircraft seats for airlines and major aircraft manufacturers in the U.S. and abroad. Weber Aircraft LLC’s headquarters and manufacturing facilities are located on a half-million-square-foot campus in Gainesville, Texas. The company also has a 120,000 square-foot service center in Atlanta, Georgia for repairs, overhauls and upgrades of aircraft interior products.

Zodiac is a global leader in the aircraft and aerospace industries, with numerous world leadership positions in a wide variety of aerosafety systems, aircraft systems and airline equipment.