CASE STUDY

Reducing Production Complexity in Aerospace Manufacturing

How a structured engineering review reduced fixture count, lowered tooling cost, and cut manufacturing time without compromising the outcome.

13 ➔ 7

Fixtures

15.3%

Cost Reduction

19.7%

Manufacturing Time Reduction

46%

Parts Count Reduction

CASE STUDY

Reducing Production Complexity in Aerospace Manufacturing


Fewer fixtures. Lower costs. Faster manufacturing.

13 ➔ 7

Fixtures

15.3%

Cost Reduction

19.7%

Manufacturing Time Reduction

46%

Parts Count Reduction

THE CHALLENGE

A technically workable process with unnecessary complexity

A Tier-1 aerospace manufacturer used 13 individual fixtures to produce a thin-walled aerospace casing.



The process worked, but it created high tooling cost, multiple re-clamping operations, longer manufacturing time, more handling risk on fragile geometry, and limited flexibility if the design changed.

High tooling cost across 13 fixtures

Multiple re-clamping operations

Longer manufacturing time

High tooling cost across 13 fixtures

Limited flexibility if the design changed

THE APPROACH

Reviewing which stages genuinely needed dedicated tooling

Cobig reviewed the full manufacturing process, challenged the existing approach, and identified where operations could be combined without adding risk.

The key question:

Which stages genuinely required dedicated tooling, and which could be combined?

Dedicated fixtures kept only where needed

Modular fixture approach introduced where practical

Process complexity reduced

Clear visibility before changes were made

THE APPROACH

Reviewing which stages genuinely needed dedicated tooling

Cobig reviewed the full manufacturing process, challenged the existing approach, and identified where operations could be combined without adding risk.

The key question:

Which stages genuinely required dedicated tooling, and which could be combined?

  • Dedicated fixtures kept only where needed
  • Modular fixture approach introduced where practical
  • Process complexity reduced
  • Clear visibility before changes were made

THE RESULT

A simpler production architecture with measurable gains

Tooling investment

£62,000 ➔ £52,500

15.3% reductiom

Manufacturing time

330min ➔ 265min

19.7% reductiom

Parts count

13 fixtures ➔ 7 fixtures

46% reduction in parts count

The client approved the revised approach and proceeded to manufacture with a clearer, lower-complexity production strategy.




Additional benefits included:

Reduced handling risk

Improved repeatability

Fewer changeovers

Greater flexibility for future design change

The client approved the revised approach and proceeded to manufacture with a clearer, lower-complexity production strategy.





Additional benefits included:

  • Reduced handling risk
  • Improved repeatability
  • Fewer changeovers
  • Greater flexibility for future design change

WHAT THIS DEMONSTRATES

What this demonstrates

The value was not in redesigning everything from scratch. It came from stepping back, challenging the current approach, and identifying where cost and complexity could be removed with losing the intended outcome.

Challenge assumptions

A fresh review can uncover simpler and more effective ways to achieve the same outcome.

Reduce avoidable complexity

Not every stage needs dedicated tooling. Combining operations can deliver significant benefits.

Protect the outcome

Cost and time can be reduced without compromising quality, performance or design intent.

Need support with a complex engineering or manufacturing challenge?

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