The Challenge
What needed to change.
A defense program faced repeated disruptions from a key single-source supplier of infrared camera lenses. Consistently late and nonconforming deliveries created cascading downstream problems:
- Production bottlenecks and assembly line stoppages
- Contractual delays with risk of penalties
- Costly rework and inspection burden
- High exposure from reliance on a single supplier with no backup
The Fulcrum Approach
How we solved it.
Fulcrum executed a comprehensive supplier recovery and development plan, addressing root causes and building long-term capability.
- Conducted a cross-functional supplier audit to map end-to-end processes, identify bottlenecks, and perform root cause analysis
- Partnered with supplier leadership to redesign the contract review and flow-down process, ensuring requirements were fully understood
- Implemented corrective actions across equipment calibration, operator training, and AS9102 first-article inspection adherence
- Introduced supplier development programs including training, mentoring, and continuous improvement practices
- Deployed real-time dashboards and supplier performance scorecards to track on-time delivery, defect rates, and process adherence
- Qualified an alternate lens supplier, eliminating single-point dependency and creating competitive leverage
Impact Delivered
Results that matter.
Outcome
On-time delivery performance restored
Outcome
Nonconformance rates and rework costs reduced
Outcome
Production bottlenecks cleared, schedule commitments recovered
Outcome
Dual-source strategy established for long-term resilience
Supplier performance stabilized, protecting program schedules and restoring customer confidence in the supply chain.