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Case StudyManufacturingAerospace

OBT in regulated manufacturing: a worked example

How an aerospace component supplier turned a process-capability gain into a register-driven commercial opportunity.

OBT Editorial July 2025 7 min read

Regulated manufacturers live in a downside-biased world: regulators ask what you have prevented, not what you have enabled. The example below — composited from three aerospace component suppliers — shows what changes when a register catches the upside of a capability investment.

The starting point

A tier-2 supplier installed in-line metrology to bring Cpk on a critical dimension from 1.33 to 1.85. The investment was justified entirely by scrap reduction. Quality logged it as a corrective-action closure. The story would have ended there.

What the opportunity register caught

Because the QMS lead had instituted an opportunity register the prior year, the capability gain triggered an entry: 'Cpk improvement opens dimensional tolerance band previously unbiddable.' Scored on the four axes:

5
Impact — opens a new product family
4
Feasibility — capability already proven
5
Strategic fit — aligned with stated growth plan
4
Time to value — 6 months to first quote

The pursuit decision

Composite score 18 of 20. The entry moved to active pursuit. Engineering and sales jointly identified two existing customers whose tighter-tolerance work had previously been declined. Within five months, one had placed a qualifying order.

Why the QMS was the right home

Strategy team would have learned about the capability gain at the next annual review — eleven months later. Sales would have learned only when the next RFQ happened to land in the new tolerance band. The QMS, because it sat next to the corrective-action closure, was the only function with both the trigger and the artifact to act now.

The capability was always there. The register is what made it visible to the people who could sell it.