Case Studies Lockheed Martin’s Flight to Perfect Quality: An iBASEt MES/Quality Customer Success Story

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	Lockheed Martin’s Flight to Perfect Quality: An iBASEt MES/Quality Customer Success Story

Lockheed Martin’s Flight to Perfect Quality: An iBASEt MES/Quality Customer Success Story

Technology Category	Analytics & Modeling - Predictive Analytics Functional Applications - Enterprise Resource Planning Systems (ERP) Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Aerospace
Applicable Functions	Quality Assurance
Use Cases	Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration Training
Challenge	Lockheed Martin’s Clearwater plant faced the challenge of maintaining high-quality standards while producing a low-volume, high-mix of ruggedized, high-reliability electronic data and signal processing equipment. The plant needed to comply with stringent specifications, regulatory requirements, and fluctuating schedules for over 30 different programs and more than 20 customers. The management team recognized the need for continuous improvement to stay competitive and achieve quality beyond market demands. A slowdown in demand during the 1990s prompted the management to focus on performance improvement, leading to the development of a culture of quality excellence and continuous improvement. Read More
About Customer	Lockheed Martin’s Clearwater facility is part of the company’s Rotary and Mission Systems (RMS) division, headquartered in Bethesda, MD. The division’s products include aeronautics, space systems, information systems, global services, and electronic systems. The Clearwater plant employs over 400 people and works with more than 500 suppliers to produce a low-volume, high-mix of ruggedized, high-reliability electronic data and signal processing equipment. The facility supports over 460 programs for U.S. military and international customers, including the U.S. Navy, Air Force, Army, Marine Corps, Coast Guard, and the Department of Homeland Security. Read More
Solution	Lockheed Martin’s Clearwater facility implemented iBASEt’s Manufacturing Execution System (MES) with an embedded Quality Management System (EQMS) to integrate production and quality assurance across operations. The MES collects data in real-time during inspection and test operations, immediately alerting on out-of-control conditions. The system also monitors metrics like defects per million opportunities (DPMO) and yield, which are used to establish process improvement goals. The MES facilitates a closed-loop system of continuous improvement by standardizing process improvements in manufacturing instructions. Additionally, the facility uses advanced technologies such as clean manufacturing cells, high-quality inspection systems, and automated solder robots to enhance quality control. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Functional Applications - Enterprise Resource Planning Systems (ERP)

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Aerospace

Applicable Functions

Quality Assurance

Use Cases

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Training

Challenge

Lockheed Martin’s Clearwater plant faced the challenge of maintaining high-quality standards while producing a low-volume, high-mix of ruggedized, high-reliability electronic data and signal processing equipment. The plant needed to comply with stringent specifications, regulatory requirements, and fluctuating schedules for over 30 different programs and more than 20 customers. The management team recognized the need for continuous improvement to stay competitive and achieve quality beyond market demands. A slowdown in demand during the 1990s prompted the management to focus on performance improvement, leading to the development of a culture of quality excellence and continuous improvement.

About Customer

Lockheed Martin’s Clearwater facility is part of the company’s Rotary and Mission Systems (RMS) division, headquartered in Bethesda, MD. The division’s products include aeronautics, space systems, information systems, global services, and electronic systems. The Clearwater plant employs over 400 people and works with more than 500 suppliers to produce a low-volume, high-mix of ruggedized, high-reliability electronic data and signal processing equipment. The facility supports over 460 programs for U.S. military and international customers, including the U.S. Navy, Air Force, Army, Marine Corps, Coast Guard, and the Department of Homeland Security.

Solution

Lockheed Martin’s Clearwater facility implemented iBASEt’s Manufacturing Execution System (MES) with an embedded Quality Management System (EQMS) to integrate production and quality assurance across operations. The MES collects data in real-time during inspection and test operations, immediately alerting on out-of-control conditions. The system also monitors metrics like defects per million opportunities (DPMO) and yield, which are used to establish process improvement goals. The MES facilitates a closed-loop system of continuous improvement by standardizing process improvements in manufacturing instructions. Additionally, the facility uses advanced technologies such as clean manufacturing cells, high-quality inspection systems, and automated solder robots to enhance quality control.

Impact #1	Lockheed Martin’s Clearwater plant has achieved a 97 percent reduction in defects over the last ten years.
Impact #2	The facility has maintained AS9100 certification and received several preferred supplier status awards.
Impact #3	The plant has implemented the LM21 Operating Excellence program, combining the Toyota production system, Lean Manufacturing, and Six-Sigma to drive continual process improvements.

Impact #1

Lockheed Martin’s Clearwater plant has achieved a 97 percent reduction in defects over the last ten years.

Impact #2

The facility has maintained AS9100 certification and received several preferred supplier status awards.

Impact #3

The plant has implemented the LM21 Operating Excellence program, combining the Toyota production system, Lean Manufacturing, and Six-Sigma to drive continual process improvements.

Benefit #1	The plant has achieved a 46.9 percent reduction in scrap/rework costs.
Benefit #2	The median finished-product first-pass yield was 98.6 percent.
Benefit #3	On-time delivery rate was 99 percent.

Benefit #1

The plant has achieved a 46.9 percent reduction in scrap/rework costs.

Benefit #2

The median finished-product first-pass yield was 98.6 percent.

Benefit #3

On-time delivery rate was 99 percent.

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Overview

Lockheed Martin’s Flight to Perfect Quality: An iBASEt MES/Quality Customer Success Story

Operational Impact

Quantitative Benefit