Read Time: 3 Min
Meeting performance specifications is the baseline for high-reliability components, but true differentiation comes from consistent availability. With this in mind, the team at the AirBorn facility in Georgetown, Texas, launched a foundational initiative that increased on-time manufacturing by 77% and reduced delivery variability by 89%, setting a new standard for supply chain performance.
Completed prior to the Molex acquisition, this year long project was led entirely by the company’s industrial engineering and digital transformation teams. Their approach offers a clear example of how focused commitment to factory fundamentals can translate directly into measurable reliability that design engineers can trust.
The Framework for Improvement
Building on a long-standing culture of continuous improvement at AirBorn, this initiative to enhance productivity and shorten lead times for Nano-D Connectors brought together internal lean manufacturing experts and digital transformation specialists. Their collaboration was critical to the project’s success, creating a proven model for achieving measurable improvements.
Executing a Methodical Redesign
The redesign effort focused on the Nano-D Connector assembly department. The first phase involved a detailed process flow analysis to identify and redesign core workflows, addressing the root causes of systemic delays rather than just their symptoms. Building on that groundwork, the second phase focused on enhancing factory planning protocols to establish a more proactive and predictable system for managing orders from start to finish. The final phase implemented critical scheduling improvements, using new digital systems to optimize the movement of work throughout the factory.
From Process to Performance
The project was guided by a key lean principle, as explained by Gus Dill, Director of Manufacturing Engineering and Continuous Improvement at AirBorn. He summarized the philosophy behind the initiative’s success: "By focusing on the flow of work and the relevant measures related to an efficient flow, the production line can better promote a smooth and uninterrupted movement through the system, minimizing delays and bottlenecks and improving customer satisfaction through reduced lead times and improved on-time delivery."
This commitment to a clear philosophy delivered compelling data-driven results. Manufacturing on-time and in-full (OTIF) improved by 77%, setting a new standard for production reliability that consistently delivered on its promises. An 89% decrease in month-to-month OTIF variability enabled lasting stability and made lead times far more predictable for customers managing tight project schedules. These internal improvements translated to a 45% increase in on-time delivery (OTD) against the customer's original promise date, -an essential metric for effective project planning. Finally, a 25% increase in overall productivity on the Nano-D Connector lines demonstrated a strengthened capacity to meet both growing and unexpected customer demand.
The Mechanics of Intelligent Planning
The driving force behind this change was a shift to a more proactive, metrics-driven planning model. This new approach reshaped how work was prioritized and moved through the production line.
From Reactive to Proactive Planning
By mapping the entire production process-from material kitting to order completion-the team achieved total workflow transparency. This insight enabled a strategic shift away from a reactive, due-date-driven system toward one based on proactive, leading metrics such as “kitted on time,” “manufacturing start on time” and “factory order finish on time." These metrics helped pull work through the system more efficiently and prevent delays before they occurred.
Accelerating Prototyping with Digital Tools
AirBorn implemented this new planning model using an intelligent, enterprise resource planning (ERP)-based scheduling system. The platform gave supervisors real-time visibility into order status and potential risks. Most importantly, it directly benefited design engineers by delivering the first 10 pieces of a Nano-D Connector order within three weeks, accelerating the customer’s design validation and prototyping.
Continuing a Foundation of Excellence
The success of this initiative set a new standard of operational discipline and customer focus that defines AirBorn as a leader in high-reliability interconnects for aerospace and defense. The full implementation of enhanced factory planning at the Georgetown facility exemplifies this commitment. It is this unwavering dedication to process improvement-demonstrated well before the acquisition and carried forward today-that makes AirBorn a powerful addition to the Molex portfolio.
By recognizing and preserving these proven methods, Molex advances this legacy of reliability, keeping it at the core of the Nano-D Connector offering.
Build your next design with confidence. See how the operational discipline behind the AirBorn N Series Nano-D Connectors helps deliver your projects on time.
Share