Barnes Aerospace Ogden

Barnes Aerospace

Read the press release here.

Overview

Barnes Aerospace Fabrications, Ogden Site is located in Ogden, Utah. Barnes Aerospace focuses on two all-encompassing strategic platforms:

  1. Our Strategy - Providing a product life- cycle solution for our customers
  2. Continual pursuit of our True North – Improving the lives of our Employees, our Customers, our Shareholders, and our communities.

We provide superior manufacturing solutions to the world's major turbine manufacturers, commercial airlines and military Original Equipment Manufacturers. As a business of Barnes Group Inc., we take advantage of the financial stability and resources of a large company, while offering the quality and service associated with smaller businesses.

Our success stems from the enthusiasm of our associates as we strive for excellence. Our lean journey has transformed our culture: from a tool and systems driven approach to an employee empowered culture which embraces the following values:

  1. Daily continuous improvement
  2. Value & principle based culture
  3. A learning organization focus
  4. Organizational team work & alignment
  5. Empowerment

These values, paired with the drive of our associates, have allowed us to continue achieving significant sustainable improvements year over year, making our True North a part of our organization’s DNA.

Throughout our lean journey, we have continued to build on our accomplishments, reducing waste and increasing efficiency while growing sales revenues by over 450%.

Product

Barnes Aerospace Fabrications, operating in a job shop environment where individual craftsmanship goes into each product, specializes in the fabrication and assembly of high temperature alloy, complex airframe and engine components with particular expertise in superplastic, hot and cold forming, welding, milling and cutting technology. Working in compliance with AS9100C standards and seven (7) special process NADCAP certifications, we deliver the highest quality and best value solutions to our customers.

Achievements

Environmental Health & Safety
  • ISO14001 certified
  • One million hours worked without a lost-time accident achieved in 2010 for the third time in BAFO history
  • Currently over 950,000 hours worked without a lost-time accident
  • Behavior Based Safety Program
Quality/Cost/Productivity
  • 53% reduction in scrap and rework as a percent of sales
  • 64% reduction in internal escapes
  • 55% lead time reduction in days to manufacture
  • 23% decrease in inventory days on hand
  • 65% decrease in freight costs per pound
Community Service
  • Annual United Way campaign and many other charitable contributions
  • Tutoring at a local elementary school
  • Year round community outreach program and quarterly sponsored events for underprivileged children
  • Barnes Aerospace Engineering Scholarship worth $5K, Weber State University
  • Service in community development and educational board of directors
Customer Satisfaction/Delivery
  • 28% increase in on time delivery
  • New product introduction on-time delivery increased from 74% to 100%
Awards & Recognition
  • 2014- The Shingo Prize for Operational Excellence
  • 2013- Utah Manufacturers Association “Manufacturer of the Year”
  • 2013- Utah Manufacturers Association “Quality Management System Award”
  • 2012- Utah Manufacturing Association and Utah Labor Commission Workplace
Safety Award for Outstanding Safety
  • 2011- Shingo Silver Medallion
  • 2009- Manufacturer of the Year Award for C. I. Utah MEP
  • Platinum Supplier, Northrop Grumman

People

Barnes Aerospace Fabrication associates have a long history of creating a culture that strives for continuous improvement and customer satisfaction in a safe working environment. Our associates make our True North strategy a success by 1) working as a cohesive team towards operational excellence; 2) continual pursuit of customer satisfaction through on- time-delivery, uncompromised quality, and pro- active communications; 3) profit growth for our shareholders; and, 4) volunteer community service.

We are benefiting from a 230% increase from 2007 in documented and implemented improvement suggestions - excluding the countless employee “just do it” daily Kaizen implemented improvements - which are leveraged across the organization. All associates benefit from a weekly “Autonomy Time” dedicated to self-improvement.

Process

Our lean journey began in 2000 by focusing on the implementation of systems and tools from the Toyota Production System. From 2000 to late 2006 improvement activities were driven from single event based activities, pushed down to associates from the leadership team, yielding low levels of sustainment.

In 2007, Ogden’s leadership team utilizing Barnes Enterprise System (BES), which closely aligns with the Shingo model, focused on teaching, empowering, aligning our systems, tools and behaviors to achieve maximum results. By unleashing the untapped human creativity of our associates, we are experiencing step change and sustained improvement activities across the entire organization.

The leadership team performs structured daily GEMBA walks, ensuring that the entire facility is engaged on a weekly basis. Leadership serves to support and remove constraints in order for our associates to deliver value and drive continuous improvement. Associates review performance measurements, as well as showcase their team’s newly implemented ideas.

Facility

In 2009, a 160,000-square-foot manufacturing facility was built using the most current lean flow tools. All of our associates participated in at least one Kaizen event centered on flow, in order to develop cell and support area layouts. Our facility houses three Value Stream operating units, each of which is focused on new product introduction, sheet metal fabrications, and airframe assemblies.

Corporation

Barnes Aerospace Fabrications Ogden division is a P & L operating segment of Barnes Group Inc. (NYSE:B), a diversified global manufacturer and logistical services company with 60 locations on four continents and 4800 employees delivering on our promises to our customers, ensuring exacting performance, superior support and service, and impactful results.

Contact

Terry Bates, Operational Excellence Specialist   |   Phone: (801) 917-2022   |   Mobile: (801) 941-4436   |   Fax: (801) 917-3000   |   Email: tbates@barnesaero.com

Barnes Aerospace Fabrications
1025 South Depot Drive
Ogden, Utah 84404-1390


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