TESTIMONIALS and CASE STUDIES

“The Platinum Source Supplier Award is recognition for your high level of quality and delivery performance as a Northrop Grumman I.S. Supplier.”
-- John Saliture, Director, Supplier Quality, Northrop Grumman

“LAI has shown, time and time again, they are dedicated to great customer service. They make sure they get the job done correctly and fulfill the customer’s requirements. I highly recommend LAI.”
-- Lee Hill, Senior Buyer, Phoenix, Ariz.

LAI provides complete design-for-manufacturing, fabrication, assembly and manufacturing solutions for highly engineered precision products. We specialize in delivering direct material productivity solutions through innovation, optimized processes, a best-in-class workforce and cutting-edge technologies. Our designers and fabricators have a wide range of experience that results in new and imaginative solutions to fit your needs. We are a turnkey supplier that excels in working with alloys, metals, composites and other exotic materials that are difficult to machine, form and fabricate.

Lean manufacturing and the use of Six Sigma principles are institutionalized in all of our facilities. LAI prides itself in having a close working relationship with its customers and has a focused market-driven philosophy. Our ability to deliver new product offerings and accelerate time-to-market is the best in the industry. We strive to live up to our identity as The Precision Manufacturing Experts by offering a variety of unique solutions to highly complex engineering problems.

F-22 Air Dominance Fighter Jet

Program Overview:

Manufacture series of 20 different highly engineered, precision-machined structural panels for mission-critical airframe components

Special Manufacturing Challenges:

Supply chain management of multi-sequenced manufacturing processes, including material acquisition, precision grinding, heat-treating, advanced waterjet machining, hot forming, alpha-case removal, five-axis trimming, drilling, counter-sinking, hardware installation, painting, finishing and inspection.

Solutions Provided:

  • A Six Sigma program completed by LAI teams has reduced production time by 20 percent for a critical structural aerospace component
  • A team of LAI employees in engineering, quality control and production formed groups to complete a comprehensive Six Sigma study that includes intensive workflow assessment, process analysis, value streaming and control planning of a manufacturing processes
  • The team examined key process input variables and studied methods to do each step more efficiently
  • An evaluation seven months after the Six Sigma project was completed revealed significant savings in the program, related to a reduction in cycle times, more efficient inspections and an overall reduction in production time by 20 percent

Award:

  • Winner of Lockheed Martin's Raptor of Distinction subcontractor award for its manufacturing excellence in producing components for the F/A-22

York Refrigeration, a Johnson Controls company

Program Overview:

York Refrigeration’s screw compressors were failing prematurely in the field, and the costly replacement of housings initiated an engineering team to find a solution. The development was urgent, due to the failures in the field of large, expensive compressors. LAI expedited the R&D and tooling and the process was proven and running production within eight weeks. LAI has laser heat-treated more than 1,500 casings since production began

Special Manufacturing Challenges:

  • Accelerated timeframe
  • Tooling to hold parts weighing hundreds of pounds
  • Universal, easy change-over tooling required
  • Demands of delivering product in two- to five-day turn time
  • Required high-tolerance precision and no distortion from laser process

Solutions Provided:

  • Manufacturing strategy that is customer centered with fast response requirements and JIT delivery
  • Real-time part status
  • Close relationship with customer’s engineers to develop prototype and work through research considerations and ensure a production-friendly process
  • Developed an integrated and shaped laser beam for maximum coverage and desired case depth and hardness
  • Applied 5-S, workplace ergonomics and other considerations, including installation of hoist for ease of prepping and loading

Testimonials:

“LAI’s laser heat treating process was a crucial part of the solution for prolonged life of our screw compressor casings.”
-- Tony Tebbutt, Compressor Design Engineer, Johnson Controls, Inc.

“LAI has been an exemplary supplier.”
-- Denise Osborne, Planner/Buyer, Johnson Controls, Inc.


Shaped Holes in Gas Turbine Nozzles

Program Overview:

Customer sought new technologies for processing advanced cooling holes for first-stage nozzles in the hot gas path of turbine engine. LAI presented a winning approach, utilizing emerging technologies. Nozzles are one of the most critical parts in the engine as they dictate how the air is presented to the turbine area of the engine.

Special Manufacturing Challenges:

  • Prototype and research considerations
  • Requirement to process the part before Thermal Barrier Coating is applied and mask cooling holes to coat.
  • Protect castings from back striking
  • High-tolerance requirements and accuracy of flow
  • Special programming requirements for 5-axis programming to 6 point datum structure that moves from casting to casting

Solutions Provided:

  • LAI developed process to machine parts post-coating
  • Produced 1,300 pieces to date
  • Developed technological innovations, including advanced Drill-to-Flow processing
  • Broke new ground on shaping technologies, transformation equations and new machine designs
  • Iterative design and manufacturing of tools that had never been built before

Modern Industries and Airbus A380

Program Overview:

Modern Industries has teamed up with Pratt & Whitney Canada to manufacture engine brackets for the Airbus A380. LAI is currently supplying Modern with more than 10 different variations for brackets that are formed and ready to assemble.

Special Customer Requirements:

  • Quick response and turnaround, high-quality parts
  • Team approach to improve process
  • Customer aims to have LAI manufacture parts complete

Special Manufacturing Challenges:

  • The production of most of the close-tolerance engine brackets require heat-treated material to be waterjet cut, de-burred, reamed, counter-sunk and formed
  • Customer currently handles the final assembly with plans to have LAI take over the entire process to produce complete parts
  • Lean manufacturing and continuous improvement is critical to insure success on this program

Solutions Provided:

Originally, the material received was wavy and difficult to process, but the LAI engineering and production team worked with the Modern Industries team to find a solution to the material issues, and Modern Industries developed upgraded tooling to improve control of the manufacturing process based on LAI's input. The team is also working with the customer to develop check fixtures for more efficient inspection of the parts.

Additional Testimonials

 

"Your company has consistently produced within budget and shipped on schedule Your noteworthy achievements are reflected in the attainment of the rating of ‘Gold’ for on time delivery. Outstanding suppliers, such as LAI Midwest, make it possible for The Boeing Company to provide quality products that set a worldwide standard of excellence."
 -- Deane R. Hislop, Director, Supplier Management & Procurement, Integrated Systems, The Boeing Company, on LAI being named supplier of the quarter

“…Their highly skilled workforce and exceptional management team have enabled them to remain competitive and support a critical technical requirement of the F/A-22 Program. They are continuously involved in process improvement projects to reduce lead times and manufacturing costs.”
-- Jim Wilsford, Lockheed Martin Aeronautics Senior Manager, on LAI being named as Lockheed Martin's Raptor of Distinction subcontractor award

“We are happy to inform you that LAI has completed all formalities required to finish the GE Supplier Certification Process. We would like to take this opportunity to thank you for your effort and dedication in this regard, as in all matters involving GE Integrity and our relationship with you.”
-- GE Supplier Certification

“LAI has been an exemplary supplier.”
-- Denise Osborne, Planner/Buyer, Johnson Controls, Inc.

“We depend on LAI International to offer manufacturing technologies above and beyond what's available from other suppliers. Ultimately, it's these technologies that drive the value we realize to hold our competitive edge. The sales team is highly knowledgeable and uses its technical expertise to assist us in determining the most economical advantage in component part manufacturing. Parts are delivered on-time, and quality has always been a priority at this supplier.”
-- Mike Getzke, Director of Business Development, 3-D CNC, Inc., Hutchinson, Minn.

“LAI’s laser heat-treating process was a crucial part of the solution for prolonged life of our screw compressor casings.”
-- Tony Tebbutt, Compressor Design Engineer, Johnson Controls, Inc.

 “On behalf of Inc.com, I am delighted to recognize your accomplishment in earning a place on the inaugural Inc. 5000 list, celebrating the fastest-growing private companies in America.”
-- Loren Feldman, Editor, Inc.com, on naming LAI to the first-ever Inc. 5000 list of the fastest-growing private companies in the United States

“MRAS considers LAI to be a full service vendor capable of supporting all facets of complex machining and manufacturing. The LAI team impressed us with their ability to find solutions to some very difficult machining problems, and with your willingness to work with MRAS, to develop just the right manufacturing approach to meet our requirements.”
-- Dr. Mahendra Mahsehwari, Director, Development Programs, Middle River Aircraft Systems, in a letter to LAI’s production team

LAI achieves 100% conformance ratings for certification of ISO 9001:2000, AS9100 and NADCAP certification for non-conventional machining in accordance with SAE Aerospace Standard AS7003.
-- NQA, an accredited organization under the Aerospace Registrar Management Program, 2008

“We are impressed! There has never been a moment that I have thought that LAI Midwest could not perform to the requirements we have required. You have always been responsive to our requests for information and product. . . . Thank you and keep up the great work!”
-- Jose Carrillo, Senior Operations Engineer, BAE Systems, in a letter to LAI’s production team