Challenge:
A newly acquired aerospace machining business had just landed a $60 million defense contract—more than ten times the company’s historical annual revenue. The upside was clear. But internally, the organization was reeling. Quality issues were spiraling out of control, rejected parts were jeopardizing the contract, and a lack of systems discipline threatened both delivery schedules and cash flow.
The company’s CEO, a sales-driven executive with vision but limited operational infrastructure, needed help—and fast. Aerosource was retained to find a multi-site Director of Quality to take control of the situation across two locations, with more acquisitions on the horizon. This was not a routine search—it was a make-or-break moment for the company.
Strategy:
We worked closely with the CEO to define a unique leadership profile: someone calm under pressure, strategically minded, but battle-tested in precision machining quality at the plant floor level. We launched a targeted search focused on candidates who had successfully led turnaround efforts under similar high-stakes conditions.
After rigorous qualification and referencing, one local candidate rose above all others. His technical credentials were impeccable—multi-division leadership experience, Six Sigma Black Belt certification, and deep knowledge of AS9100 and NADCAP. But what truly set him apart were the references. One former colleague, a seasoned aerospace manufacturing leader, called him “the best quality professional in the country for precision machining,” citing unmatched work ethic, technical competence, and character.
Results:
The candidate was hired and immediately went to work stabilizing operations. He restructured the company’s quality organization, rewrote the Quality Manual, and instituted standardized systems and processes across both sites. Most critically, he stemmed the tide of costly returns and quality escapes, putting the company back on track to meet contractual requirements and restoring customer trust.
The improvement in quality performance led to increased on-time delivery, reduced rework, improved cash flow, and set the foundation for profitability. His calm leadership style and principled management earned him the respect of the entire organization. Within 18 months, he was promoted to multi-site Vice President of Quality, and General Manager.
This search became a cornerstone success story. Since then, Aerosource has completed six additional leadership and technical searches for the company, all contributing to the operational and cultural transformation that followed.