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Overview
Overview
A leading aerospace R&D center specializing in Laser Powder Bed Fusion (LPBF) faced repeated delays in receiving critical metal powder shipments. With only 53% of orders delivered on time and two recent rejections for hazmat non-compliance, research timelines and OEM trust were at risk. A rejected 50 kg shipment in early 2024 caused a 3-week standstill, jeopardizing multi-million-pound projects.
The Challenge
The Challenge
The customs rejection exposed severe vulnerabilities: incorrect UN packaging, missing hazard labels, damaged crates, and inaccurate emergency documentation. Supplier delays, combined with a 2–3 week backlog from freight partners, amplified the disruption. Root cause analysis revealed single-supplier dependency, lack of safety stock, poor SOPs, and limited visibility on lead times—all threatening project milestones and strategic OEM relationships.
The Solution
The Solution
AEM Consultancy designed a rapid recovery and long-term risk-mitigation plan:
Implemented a Hazmat Compliance Checklist for all shipments.
Revised SOPs for inspections, emergency sourcing, and buffer stock.
Rolled out cross-functional hazmat training across procurement, QC, lab, and operations.
Onboarded a secondary supplier, reducing dependency.
Launched live inventory dashboards and quarterly supplier reviews.
Introduced a 2-week safety stock policy to absorb future shocks
Results
Results
Within 8 weeks:
LPBF operations were fully restored.
Dependency risk reduced by 80% with dual-sourcing.
Safety stock ensured zero disruption in the next cycle.
Avoided £50,000+ in delay penalties and £12,000+ in freight costs.
Established a validated hazmat logistics framework for future materials.
This transformation not only stabilized operations but also positioned the client for long-term resilience and safer supply chain practices.
Want to build a more resilient, data-informed, and scalable operations system in your manufacturing or R&D organization? Please contact AEM Consultancy
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