KBSI's approach was to first implement the strategies identified during Phase I in a series of pilots. The pre-shop analysis, disassembly, and assembly processes were streamlined. A standardized disassembly and assembly methodology was created and piloted for the Blackhawk. The Team redesigned the shop workstation layout and assisted in the set-up of a single site disassembly annex. A kitting and staging process was also implemented. The kitting system, Kit Content History Reporting tool (KCHR), continues to provide production control and management with complete visibility of parts and components in inventory.

Utilizing KBSI’s kit staging strategy and KCHR tool, CCAD experienced improved asset visibility and reduced AWP. Prototyped implementations resulted in a 30% reduction in the PSA process cycle time, a 75% reduction in PSA parts route delays, and an increased throughput capability in PSA disassembly of 400%. KBSI was further successful in developing an improved Quick Change Assembly/Small Parts flow and helped to resolve several debilitating quality issues. The overall assembly cycle time of a UH-60 Blackhawk was reduced from 220 days to 73 days.