Case Studylean

Rockwell Collins Lean Journey acheives decades long success

Rockwell Collins (now Collins Aerospace) CEO Clay Jones launched a Lean Electronics program in 1997. I joined the organization in Jan 1999, and was part of a massive transformation of Lean and Six Sigma methods that was still going strong when I left in 2017. Many improvement initiatives don’t last 3 years, so this is indeed a success story.

As an example of the success of the program, they acheved the following success in an office environment (publishing)

  • 72% reduction in publishing cycle time
  • 70% WIP reduction
  • 38% productivity improvement
  • 77% manuals inventory reduction

In the manufacturing area, they achieved the following results:

  • 25% productivity improvement
  • 46% reduction in inventory
  • Cycle time reductions of 75% and greater

I will list some specific projects I worked on in other case studies, but I am very proud of the work I did to help bring Six Sigma into the program, help the initiative continue through a few ups and downs, help deploy it to two different facilities (Melbourne and Wilsonville) and change the culture through numerous conversations and teaching opportunities I had with employees, managers, suppliers and customers.

You can learn more about the history of Lean Electronics from a 2006 speech from Clay Jones.


Want to learn more about Lean and Six Sigma tools, and apply them to an improvement projects? Check out these low-cost online courses and certification programs



Earn a 33% commission for selling our digital products. Learn more
Let us sell your products on our store. Learn more
Join Waitlist We will inform you when the product arrives in stock. Please leave your valid email address below.

No fields found, please go to settings & save/reset fields