Lean Coaching & PAC Tooling Project Delivery

Client: Airbus, Global Aerospace Manufacturer

Led by: Lee Bellis, GEMBEX Founding Consultant

Airbus engaged with Lee to enhance operational performance and consistency across its production environment. The initiative focused on embedding Lean principles, improving process flow, and aligning technical projects with strategic business goals.

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  • Embed Lean tools and thinking across operational teams

  • Improve process efficiency, reduce variability, and enhance flow

  • Deliver cross-functional projects with measurable performance gains

  • Align tooling initiatives with long-term strategic objectives

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  • Lean Coaching & Deployment: Delivered hands-on coaching in standardised work, 5S, Heijunka (level loading), VSM, Kanban, and KPI tracking to drive clarity and operational discipline

  • Process Implementation: Led the rollout of new processes that improved efficiency, reduced waste, and enhanced consistency across teams

  • PAC Tooling Project: Oversaw the PAC Tooling Project from planning to execution, ensuring strategic alignment and measurable improvements in tooling performance and reliability

  • Project Management: Applied structured project management to coordinate cross-functional teams, manage risk, and ensure timely delivery of outcomes

A black background with gold-colored starburst shapes and the word 'Results' in gold text.

  • Lean tools embedded across key operational areas

  • Improved process flow and reduced variability

  • PAC Tooling Project delivered enhanced reliability and strategic alignment

  • Strengthened team capability and continuous improvement culture

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This project demonstrated the impact of combining Lean principles with disciplined project execution.
By aligning technical delivery with strategic intent and coaching teams on the ground, Airbus achieved
sustainable improvements in performance, reliability, and operational culture.