Case Studies
"Theory explains the framework. Real examples prove it works."
This page contains detailed case studies showing how the 6D Foraging Methodology reveals cascading costs in real-world scenarios.
Case Study 1: Aviation Maintenance Facility Parts Inventory Crisis
Industry: Aviation/Aerospace Maintenance Company Size: $200M annual revenue, 500 employees Problem Duration: 6 months Analysis Date: November 2025
Executive Summary
A major aviation maintenance facility experiencing recurring parts inventory issues leading to aircraft downtime and maintenance delays. Initial estimate: $119K annually in direct labor and material waste.
6D Analysis revealed:
- Total Impact: $2,200,000
- Multiplier: 18.5×
- Dimensions Affected: All 6
- Cascade Depth: 2 levels
Background
What happened:
- Parts inventory management system inadequate for demand variability
- Recurring stockouts causing aircraft maintenance delays
- Issue persisted for 6 months before comprehensive analysis
- Affected all maintenance operations across multiple aircraft types
Initial response:
- Expedited parts orders at premium costs
- Technician overtime waiting for parts
- Rushed repairs when parts finally arrived
- Customer notifications of delays
Traditional cost analysis:
Expedited shipping costs: $42,000 annually
Wasted labor (waiting): $35,000 annually
Material waste (wrong parts ordered): $28,000 annually
Inventory carrying costs: $14,000 annually
───────────────────────────────────────────
TOTAL (Traditional): $119,000Executive decision: "Improve inventory processes. Annual cost: $119K."
6D Impact Analysis
Step 1: Identify Origin Dimension
Origin: Operational (D6)
Observable signals:
- Recurring parts stockouts
- Expedited orders pattern
- Extended aircraft downtime
- Maintenance schedule disruptions
Data sources checked:
- Inventory management system
- Aircraft maintenance logs
- Customer contract performance reports
- Technician timesheet data
Step 2: Score Origin Using 3D Lens
| Lens | Score | Reasoning |
|---|---|---|
| Sound (Urgency) | 8 | Critical operations — all maintenance bays impacted |
| Space (Scope) | 7 | All maintenance operations, multiple aircraft types |
| Time (Trajectory) | 7.5 | Persisted 6 months, accelerating as fleet grows |
Origin Score: (8 × 7 × 7.5) ÷ 10 = 42.0 (High severity)
Step 3: Map Cascade Pathways
LEVEL 0: Operational (Origin)
- Direct Cost: $119,000 annually
LEVEL 1 CASCADES:
CASCADE 1: Operational → Quality (80% probability)
Observable signals:
- Aircraft maintenance delays (AOG incidents increased 35%)
- Extended aircraft downtime (average +18 hours per maintenance event)
- Rushed repairs when parts finally arrived
- Quality inspection failures due to rushed work
- Maintenance rework required on 12% of jobs
3D Scoring:
- Sound = 8 (Aircraft safety-critical, customer-visible)
- Space = 7 (All maintenance bays, multiple aircraft types)
- Time = 6 (Recurring weekly for 6 months)
- Score: 28.0
Multiplier factors:
- Detection point: Customer complaints about delays (3.5×)
- Fix complexity: Aircraft downtime costs are severe (4×)
- Scope: All maintenance operations (3×)
- Average: 3.5×
Cost calculation:
Base: $119K × 80% probability = $95,200
Multiplier: 3.5×
CASCADE COST: $330,000Cost breakdown:
- Extended aircraft AOG (Aircraft On Ground) costs: $145,000
- Rushed repair quality issues / rework: $82,000
- Re-inspection requirements: $58,000
- Quality assurance process enhancement: $45,000
CASCADE 2: Operational → Employee (75% probability)
Observable signals:
- Technician overtime hours up 42% (waiting for parts)
- Maintenance supervisor working weekends coordinating parts
- "Inventory system is broken" comments in team meetings
- 3 senior technicians exploring other opportunities
- Morale survey scores dropped from 7.8 to 6.2
3D Scoring:
- Sound = 7 (Active complaints, turnover risk)
- Space = 6 (All maintenance technicians affected)
- Time = 6.3 (Sustained pressure over 6 months, worsening)
- Score: 26.5
Multiplier factors:
- Role criticality: FAA-certified A&P mechanics, specialized (5×)
- Knowledge concentration: Aircraft-specific expertise (4×)
- Replacement time: 90-120 days for certified mechanics (3.5×)
- Average: 4.2×
Cost calculation:
Base: $119K × 75% probability = $89,250
Multiplier: 4.2×
CASCADE COST: $370,000Cost breakdown:
- Overtime hours (650 hours @ $85/hr with premium): $82,875
- Morale impact / reduced productivity (6 months): $125,000
- Technician retention bonuses to prevent turnover: $92,000
- Recruiting and training costs for 2 replacements: $70,125
CASCADE 3: Operational → Revenue (65% probability)
Observable signals:
- Penalty clauses triggered in 4 major airline contracts
- 2 airlines threatening contract termination
- Lost expansion opportunity with new airline customer
- Reputation damage in tight-knit aviation industry
- Contract renewal negotiations stalled pending resolution
3D Scoring:
- Sound = 9 (Active revenue loss, contract termination threats)
- Space = 6 (Major airline contracts, industry reputation)
- Time = 6.7 (Recurring delays, pattern damaging relationships)
- Score: 36.0
Multiplier factors:
- Revenue concentration: Top 3 airlines = 65% of revenue (12×)
- Contract type: Multi-year agreements with strict SLAs (11×)
- Industry impact: Aviation maintenance market is relationship-driven (11×)
- Average: 11.4×
Cost calculation:
Base: $119K × 65% probability = $77,350
Multiplier: 11.4×
CASCADE COST: $880,000Cost breakdown:
- Contract penalty clauses paid: $285,000
- Lost expansion contract (1 new airline): $340,000
- Revenue at risk from contract termination threats: $185,000
- Executive time managing airline relationships: $70,000
LEVEL 2 CASCADES:
CASCADE 4: Quality → Customer (85% probability)
Observable signals:
- Major airlines questioning maintenance reliability at quarterly reviews
- "Need detailed reporting on every delay" requirement added
- Contract renewal discussions requiring performance improvement plans
- One airline conducting their own audit of maintenance practices
- Lost reference opportunity from previously satisfied customer
3D Scoring:
- Sound = 7 (Direct complaints, detailed reporting mandates)
- Space = 7 (All major airline customers reviewing relationships)
- Time = 5.8 (Pattern over 6 months, stabilizing with improvements)
- Score: 27.5
Multiplier factors:
- Customer size: Major airlines with large fleets (2×)
- Relationship length: 5-8 year relationships at risk (1.5×)
- Industry reputation: Aviation is relationship and reputation-sensitive (1.3×)
- Average: 1.6×
Cost calculation:
Base: $330K (Quality cascade) × 85% probability = $280,500
Multiplier: 1.6×
CASCADE COST: $440,000Cost breakdown:
- Executive time for airline relationship recovery: $110,000
- Enhanced reporting and documentation systems: $85,000
- Customer audit accommodation costs: $145,000
- Lost cross-sell opportunities during recovery period: $100,000
CASCADE 5: Revenue → Regulatory (30% probability)
Observable signals:
- FAA concerns about parts traceability documentation
- Missing records for critical parts installation
- Audit trail gaps in maintenance documentation for 6 months
- Potential need for supplemental airworthiness documentation
- Internal compliance team flagged inventory controls
3D Scoring:
- Sound = 6 (FAA concern raised, not yet violation)
- Space = 4 (Parts inventory process, maintenance department)
- Time = 4.6 (6-month gap, now being remediated)
- Score: 11.0
Multiplier factors:
- Industry regulation: Aviation/FAA = very strict (0.3×)
- Violation severity: Documentation gaps, not safety violations (0.2×)
- Remediation complexity: Documentation enhancement needed (0.2×)
- Average: 0.23×
Cost calculation:
Base: $880K (Revenue cascade) × 30% probability = $264,000
Multiplier: 0.23× (preventive audit, not fines)
CASCADE COST: $61,000Cost breakdown:
- External FAA compliance consultant: $28,000
- Internal audit of parts traceability: $18,000
- Documentation system enhancement: $10,000
- Management time for compliance remediation: $5,000
Step 4: Calculate Total Impact
┌─────────────────────────────────────────────────────────┐
│ 6D IMPACT ANALYSIS SUMMARY │
├─────────────────────────────────────────────────────────┤
│ │
│ LEVEL 0 (Origin): │
│ Operational (D6): $119,000 │
│ │
│ LEVEL 1 (Primary Cascades): │
│ Quality (D5): $330,000 │
│ Employee (D2): $370,000 │
│ Revenue (D3): $880,000 │
│ │
│ LEVEL 2 (Secondary Cascades): │
│ Customer (D1): $440,000 │
│ Regulatory (D4): $61,000 │
│ │
├─────────────────────────────────────────────────────────┤
│ │
│ DIRECT COST: $119,000 │
│ CASCADE COST: $2,081,000 │
│ ───────────────────────────────────────────── │
│ TOTAL IMPACT: $2,200,000 │
│ │
│ MULTIPLIER: 18.5× │
│ │
│ Dimensions Affected: 6/6 │
│ Cascade Depth: 2 levels │
│ │
└─────────────────────────────────────────────────────────┘Before vs. After Comparison
| Metric | Traditional Analysis | 6D Impact Analysis | Delta |
|---|---|---|---|
| Total Cost | $119,000 | $2,200,000 | +1749% |
| Dimensions Analyzed | 1 (Operational) | 6 (All) | +500% |
| Cascade Levels Mapped | 0 | 2 | N/A |
| Time Horizon | Annual direct costs | Full annual impact | Extended |
| Customer Impact Considered | No | Yes ($440K) | N/A |
| Employee Impact Considered | Overtime only | Full turnover risk ($370K) | +211% |
| Regulatory Risk Assessed | No | Yes ($61K) | N/A |
Lessons Learned
1. Early Detection Would Have Prevented 60% of Cascade
Root cause timeline:
- Issue began: Month 1 (demand exceeded inventory system capacity)
- First signal (stockout pattern): Month 2, Week 1 (treated as isolated)
- Second signal (customer complaints): Month 3, Week 2 (explained as supply chain issue)
- Comprehensive analysis: Month 7
If caught in Month 2:
- Quality cascade: Reduced by 70% (fewer delays, less rushed work)
- Customer cascade: Prevented (trust maintained with proactive communication)
- Employee cascade: Reduced by 65% (quick fix vs. 6-month frustration)
- Revenue cascade: Prevented (no penalty clauses triggered)
Estimated impact if caught early: $119K direct + $180K cascades = $299K total (7.4× smaller)
2. Revenue Dimension Had Highest Impact Due to Contract Penalties
Cascade probability vs. severity:
| Cascade | Probability | Cost | Risk-Adjusted Cost |
|---|---|---|---|
| Quality | 80% | $330K | $264K |
| Employee | 75% | $370K | $277.5K |
| Revenue | 65% | $880K | $572K |
| Customer | 85% (via Quality) | $440K | $374K |
| Regulatory | 30% (via Revenue) | $61K | $18.3K |
Strategic lesson: Aviation industry contract penalties create severe revenue cascades that justify significant preventive investment in operational excellence.
3. Employee Turnover Risk Was Severely Underestimated
Visible cost (overtime): $82,875
unmeasured costs:
- Reduced productivity during crisis: $125,000
- Retention bonuses to prevent departures: $92,000
- Recruiting and training replacement technicians: $70,125
Total employee impact: $370,000 (4.5× the visible overtime cost)
Management error: Underestimating the cost of replacing FAA-certified aviation mechanics with specialized aircraft knowledge.
4. Regulatory Cascade Was Preventable with Better Parts Traceability
Trigger: FAA concerns about parts traceability documentation gaps for 6 months
Prevention cost: $8,000
- Enhanced parts tracking system: $5,000
- Real-time documentation process: $3,000
Actual cost: $61,000 (7.6× the prevention cost)
Lesson: In aviation, regulatory cascades are highly preventable with proper documentation and traceability controls upfront.
Preventive Measures Implemented
Based on this 6D analysis, the company implemented:
Immediate (< 1 week)
Parts demand forecasting enhancement
- Implement predictive analytics for parts demand
- Cost: $25,000
- Prevents: Recurring stockouts and delays
- ROI: Prevents $2M+ in future cascades
Airline customer communication protocol
- Proactive notifications for any maintenance delay >4 hours
- Cost: Process documentation only
- Prevents: Customer trust erosion and contract penalties
Short-term (1-3 months)
Inventory management system upgrade
- Real-time parts tracking and automatic reordering
- Cost: $85,000 (one-time) + $5K/month
- Prevents: $330K Quality cascade + $880K Revenue cascade
Technician workload balancing
- Cross-training on multiple aircraft types to reduce wait times
- Cost: $45,000 (training)
- Prevents: $370K Employee cascade
Long-term (3-6 months)
FAA compliance documentation automation
- Automated parts traceability and maintenance documentation
- Cost: $60,000 (one-time)
- Prevents: $61K Regulatory cascade
Customer relationship management enhancement
- SLA monitoring dashboard for airline customers
- Proactive performance reporting
- Cost: $35,000 (system integration)
- Prevents: $440K Customer cascade
Total preventive investment: $250K (one-time) + $5K/month
Cascade impact prevented: $2.08M annually (8.3× ROI in first year)
ROI of 6D Analysis
| Metric | Value |
|---|---|
| Time to conduct 6D analysis | 8 hours (analyst time) |
| Cost of analysis | $1,600 |
| Preventive measures identified | 6 |
| Total preventive investment | $250K one-time + $60K/year |
| Cascade cost prevented (annual) | $2.08M |
| Net benefit (Year 1) | $1.77M |
| ROI | 571% |
Case Study 2: [Coming Soon]
Industry: Healthcare Scenario: Hospital-acquired infection spike Focus: Quality → Regulatory cascade with 15× multiplier
Case Study 3: [Coming Soon]
Industry: Manufacturing Scenario: Production line equipment failure Focus: Operational → Revenue cascade in JIT environment
Case Study 4: [Coming Soon]
Industry: Financial Services Scenario: Trade error affecting high-net-worth client Focus: Quality → Customer cascade with relationship concentration risk
How to Submit Your Case Study
Have a 6D Impact analysis from your organization? We'd love to feature it (anonymized).
Submission criteria:
- Complete 6D analysis (all dimensions scored)
- Cascade pathways mapped (at least 2 levels)
- Before/after cost comparison
- Lessons learned documented
Contact: Submit via GitHub Issues
Next Steps
Remember: Every problem tells a story. The 6D framework helps you read the whole book, not just the first page. 🪶