Shift left in Aerospace Manufacturing Processes – Build an Intelligent Manufacturing Factory

Aerospace and defense companies aren’t just being asked to do more; there are demands to produce better quality and do it faster than ever with fewer resources. That’s why any investment aimed at optimizing production processes must be strategic.

The factory of the future can be built today. By creating comprehensive digital twins of not only products but of the machines and processes used in manufacturing, aerospace, and defense companies have the power to build intelligent manufacturing programs that increase production flexibility and bring new products to market than the competition.

This brief explores the benefits of connecting manufacturing to the product lifecycle from the time of a project’s inception, as well as how the use of mixed reality solutions, lead to fewer late design changes and more reliable products.

Accelerate ramp-ups in aerospace manufacturing

Companies relying on manual processes and legacy tools struggle to optimize factory layout and work from assumptions of the efficiency of their processes. This labor-intensive method is detrimental to production ramp-up.

Although most A&D executives are keenly aware of the benefits of automation, too often mistaken beliefs to cause leadership to block the path toward digitalization.

A common misconception is that relatively few annual projects cannot justify the investment. However, they often grossly underestimate the costs needed to start a new program. Companies using historical data for ramp-up planning find the true costs are nearly double their initial estimates with today’s stricter oversight and complex customer demands.

This brief illuminates the damage resistance to automation creates on the success of A&D programs, as well as how companies adopting a holistic approach to automation improve quality and deliver products faster. Further, we explain how building a clone of a virtually designed, tested, and validated factory accelerates production rate ramp-up times.

Closed-Loop Manufacturing in Aerospace

Reliance on paper-based work instructions has traditionally been the method for manufacturing teams. Each part moving through the production process must have its documentation attached, and it must be the most up-to-date version. When that paper trail goes cold or, perhaps even worse, is not accurate, bottlenecks emerge.

By adopting an approach that is digital and connected, manufacturing technicians not only can be assured they have the most current information, they also have the ability to use augmented reality to “see” exactly how the project is intended to be manufactured and perform within a system.

Benefits of Digital Twin and Virtual Simulation

By digitally replicating every aspect of production aerospace companies are capable of simulating all of their processes, exposing potential problem areas, and eliminating bottlenecks before they occur. When setting up a new factory line, or designing the layout of an entirely new facility, having the tools to visualize the layout, employee interaction with the machines, and the ability to explore "what-if" scenarios helps ensure production processes are optimized.