Elevating KPI Tracking and Operational Efficiency in Defense Manufacturing with iGEMBA
A U.S. defense manufacturer monitored KPIs on paper during Gemba walks, with little visibility across SDQC and no history for root cause analysis. iGEMBA replaced paper with live KPI dashboards, smart visualisation and tracked issue resolution.
- Client
- U.S. defense manufacturer of weapon systems, missile parts and ammunition
- Industry
- Aerospace and defense
- Solution
- ITHENA Digital Shopfloor (iGEMBA)
- Scope
- Digital KPI dashboards, SDQC visibility, KPI history, issue tracking
- Headline result
- 32% higher productivity
Three numbers the defense shop floor moved.
Results after Gemba walks moved from paper to iGEMBA.
Boost in overall productivity
Hours of paper-based KPI reporting disappeared from every week.
Reduction in decision-making time
Live dashboards put SDQC performance in front of leaders during the walk.
Increase in operational efficiency
Historical KPI access and tracked issues made root cause analysis routine.
Meet the organization and understand the context behind the transformation.
The client specializes in designing, developing, and manufacturing weapon systems, missile parts, and ammunition. To address challenges with delayed decision-making, limited visibility into performance metrics, and a lack of comprehensive root cause analysis, they implemented ITHENA’s iGEMBA solution. By transitioning to real-time KPI tracking, smart visualization tools, and automated alerts, the company significantly enhanced operational efficiency, boosted productivity, and reduced decision-making time, positioning them for continued success in a demanding industry.
I just posted an entire week of material to these programs for reporting in about 30 minutes. Used to take me 15+ hours all during the week. YAY!!!!
-Enloa, End User
Gemba walks slowed by paper.
KPI monitoring was manual, so trends went unseen and issues were found late.
- Delayed decision-making and action due to time-consuming paper-based KPI monitoring during Gemba walks
- Inability to identify trends and patterns for proactive management of shop floor incidents
- Limited visibility into key performance indicators across SDQC
- Unavailability of historical data to conduct thorough root cause analysis (RCA) and developing targeted corrective actions
How ITHENA closed the gaps.
ITHENA’s Digital Shopfloor (iGEMBA) solution provided the client with:
Digital KPI Dashboard
Digitized dashboards enabled users to define organizational hierarchy and KPIs for a unified view of shop floor performance
Smart Visualization
Persona-based visualization of KPI formulas and color thresholds for clear performance insights
Historical KPI Access
Provided access to historical data of KPIs for easy comparison of current observations with past trends, enabling effective pattern analysis
Proactive Issue Resolution
Streamlined efficient task tracking and issue resolution related to KPI breaches
Persona-based Access
Secured platform with permissions tailored to user personas
SDQC breaches, caught on the walk.
An illustrative iGEMBA view: safety, delivery, quality and cost tracked live, with every breach turned into a tracked issue.