The aim of this thesis is to analyze the product development process at GKN Aerospace based on the strength of the conscious alignment between the intended standardized work by the Quality Management System (QMS) and the actual conduction of the process. The analysis is executed within the perspective of “Design for Quality” for design engineers at the company and takes ongoing adaptation to the evolving needs and conditions of the aerospace industry into account. Through a combination of process analysis, internal documentation and literature review, interviews and observations conducted, the thesis explores how the A3-approach within lean methodology can shed light on the subject.

In this context the identification of root causes builds a deeper understanding of the context, specifically from a design-engineer perspective. Key factors with most impact on the strength of alignment between everyday conduction and QMS-intended way-of-working include varying personal interpretations and utilization of resourceful documentation. Moreover, the increasing complexity and novelty of AM in combination with evolving customer requirements is identified to add pressure on the subject and the organization's goal to maintain high-quality standards and regulatory compliance. The A3 methodology was applied to systematically identify root causes in the context of the work. Within the A3 approach lean tools including the Ishikawa diagram, the problem definition tree and a KNOT analysis were applied.

The results indicate that the existing culture of engaged employees and excellent communication is a stable foundation to implement improvement work. Areas identified for aimed improvement activities include efficient training on the right level and competence and optimized processes related to comprehensive documentation. The thesis showcases the effective utilization possible within the lean mindset on the A3-approach used. The thesis concludes that GKN Aerospace demonstrates significant potential for improvement work by addressing the identified root causes through continuous improvement work. Successful implementation can be expected to enhance operational efficiency and employment satisfaction, ultimately aligning the daily work even more close to the overarching company goal of “being the most trusted partner in the sky”.