Case StudiesManufacturingPrecision Manufacturing Co.
Manufacturing

Precision Manufacturing Reduces Safety Incidents by 74% with Certified Workforce

An aerospace manufacturer solves the skilled trades shortage while achieving safety excellence

ManufacturingAerospaceSafetyApprenticeship

Precision Manufacturing Co.

Aerospace Manufacturing

8,000+ employees
Wichita, KS
Founded 1965
-74%
Safety Incidents
-51%
Time-to-Fill (Skilled)
+12%
Certification Compliance
+47%
Apprentice Retention
-65%
Quality Defects
-51%
Training Costs

Overview

Precision Manufacturing Co., a Tier 1 aerospace supplier, was struggling to find qualified CNC machinists and welders as their experienced workforce approached retirement. With strict FAA quality requirements and a commitment to safety, they needed a solution that could verify skills and certifications while building a pipeline of next-generation talent.

The Challenges

Skilled Trades Shortage

35% of workforce eligible for retirement within 5 years, with insufficient pipeline of qualified replacements.

Safety Certification Tracking

Manual tracking of 47 different safety certifications across 8,000 employees leading to compliance gaps.

Quality Requirements

FAA AS9100 certification requires documented training and competency verification for all production staff.

Union Coordination

Complex hiring rules under collective bargaining agreement requiring careful process documentation.

The Solutions

Skills Assessment Platform

Implemented hands-on skills testing for CNC programming, welding, and blueprint reading with digital certification.

CNC programming testsWelding certification trackingBlueprint reading assessmentDigital skills matrix

Safety Certification Management

Automated tracking of all safety certifications with expiration alerts and renewal workflows.

OSHA certification trackingForklift license managementLockout/tagout verificationAutomated renewal alerts

Apprenticeship Pipeline

Built partnerships with trade schools and community colleges for registered apprenticeship programs.

Trade school partnershipsRegistered apprenticeshipsVeteran transition programsHigh school career pathways

Implementation Timeline

Assessment Development

6 weeks

Created skills assessments with input from master craftspeople and quality engineers.

Skills matrix defined
Assessment content created
Scoring rubrics calibrated
Pilot testing completed

Certification Integration

4 weeks

Migrated all safety certification records and established automated tracking workflows.

Historical records migrated
Expiration alerts configured
Renewal workflows live
Compliance dashboard deployed

Pipeline Development

8 weeks

Established apprenticeship programs and educational partnerships.

6 trade school partnerships
DOL apprenticeship registered
Veteran program launched
High school program piloted

Union Integration

4 weeks

Configured workflows to comply with collective bargaining agreement requirements.

CBA rules documented
Seniority tracking enabled
Bid posting automated
Union reporting configured

The Results

-74%
Safety Incidents
4.2/1001.1/100
-51%
Time-to-Fill (Skilled)
45 days22 days
+12%
Certification Compliance
89%100%
+47%
Apprentice Retention
62%91%
-65%
Quality Defects
2.3%0.8%
-51%
Training Costs
$8,500$4,200

FAA Audit Excellence

Achieved zero findings in annual FAA AS9100 audit for workforce documentation.

Apprenticeship of the Year

Recognized by Department of Labor for outstanding registered apprenticeship program.

$2.1M Safety Savings

Reduced workers' compensation costs through improved safety performance.

What They Say

"The skills assessment platform transformed our hiring. We can now verify that candidates actually have the machining skills they claim, which has dramatically improved quality and safety."

Robert Martinez
Plant HR Director

"Our safety record is the best it's been in 20 years. Knowing that every employee has current certifications gives us confidence on the production floor."

James Wilson
Safety Director

"The apprenticeship pipeline is solving our succession crisis. We're developing the next generation of skilled craftspeople who will carry on our legacy of quality."

Linda Thompson
VP of Operations

Share This Case Study

Ready for Similar Results?

See how Nexus can transform your manufacturing hiring.