In the high-stakes world of aerospace manufacturing, every part you produce must be a masterpiece of precision. Each stage of the supply chain demands perfection so when it’s time to fly, everyone aboard feels safe. To accomplish this, manufacturers must balance innovation with strict quality control.
Let’s explore the nuances of the aerospace parts manufacturing industry and critical strategies for improvement. Keep reading to learn more, or jump to the bottom to discover how Fishbowl can help you achieve peak performance.
What is aerospace manufacturing?
Aerospace manufacturers create parts for aircraft, spacecraft, and defense systems like missiles. Aerospace parts manufacturing stands apart from other industries due to stringent protocols and the need for absolute precision.
Any materials and components for airborne objects have to function under extreme conditions, like high altitudes, fluctuating temperatures, and immense barometric pressure. As a result, the aerospace sector operates under tight regulations. To comply, manufacturers have to ensure every component’s safety and durability
The aerospace engineering and manufacturing industry supply chain
A robust supply chain is the backbone of any successful aerospace parts manufacturing operation. This web of suppliers and manufacturers ensures that every component meets safety and performance standards, from raw materials to assembled parts.
Key components of the aerospace supply chain include:
- Raw material suppliers: These companies provide specialized metals, composites, and other resources like electricity that manufacturers transform into components. Having reliable raw material suppliers is vital because manufacturers must follow strict production schedules and create high-quality parts.
- Component manufacturers: Once aircraft parts manufacturers source raw materials, they develop components — the building blocks of any aerospace system. These components must meet exact specifications to ensure they function correctly within complex systems.
- Assembly and integration: At this stage of the supply chain, a company combines manufactured components to form larger systems, such as engines or entire aircraft. The company needs highly skilled workers and complex machinery so everything fits together seamlessly.
- Testing and certification: Before any aerospace part or aircraft is cleared for use, it needs rigorous testing to make sure it can withstand the demands of flight. Most parts must also get certifications from regulatory bodies to confirm they meet industry standards and safety regulations.
Considerations for aerospace manufacturers
Aerospace components manufacturers must navigate multiple regulations and industry standards to ensure safety and performance. Here are some essential guidelines and certifications to keep in mind:
AS9100D certification
AS9100D is the most up-to-date quality management standard designed specifically for the aerospace industry. It incorporates the core elements of ISO 9001:2015, a more general international quality management standard, but it adds additional requirements unique to aviation, space, and defense. In aerospace manufacturing, AS9100D certification is often a baseline requirement.
International Traffic in Arms Regulations (ITAR)
ITAR is a set of U.S. regulations for aerospace manufacturers involved in defense contracts or the production of military-grade technology. It governs imports and exports to protect national security. Compliance with ITAR is mandatory, and non-compliance has hefty consequences like fines and blacklisting.
AS9102 First Article Inspection Reports (FAIRs)
FAIRs document that the first production run of a new or modified product meets all design, material, and performance specifications. This process helps you address any issues before large-scale production, reducing the risk of defects in subsequent units. FAIRs are a critical part of maintaining quality and safety and making sure your manufacturing process is up to par.
AS9145 Advanced Product Quality Planning (APQP)
APQP is a standard that guides aerospace manufacturers through the product development cycle. It provides a structured approach for planning and verifying that aerospace products meet customer and regulatory requirements. The final step of APQP is the production part approval process (PPAP), where manufacturers submit proof that their production processes consistently produce quality parts.
AS6081: Counterfeit Electronic Parts
AS6081 requires aerospace manufacturing companies to establish strict procedures for sourcing, inspecting, and tracking materials. This prevents counterfeit or substandard parts from entering the supply chain. Compliance with AS6081 is critical for maintaining product integrity and safety in aerospace systems.
National Aerospace and Defense Contractors Accreditation Program (NADCAP)
NADCAP is the National Aerospace and Defense Contractors Accreditation Program — a global cooperative program that audits aerospace manufacturing processes like welding and heat treating. By gaining NADCAP accreditation, you prove that your processes meet the highest industry standards and position your company as a trusted supplier in the aerospace and defense sectors.
ISO 14001
ISO 14001 is an international standard for managing environmental risk. It’s not specific to aerospace manufacturing, but it’s relevant because of industry concerns like high energy consumption, material use, and emissions. By complying with ISO 14001, aerospace manufacturers can make their processes more sustainable — crucial in a sector increasingly focused on environmental responsibility.
ISO 45001
ISO 45001 governs occupational health and safety management. Like ISO 14001, ISO 45001 isn’t specific to the aerospace industry. But compliance is crucial for aerospace manufacturers due to the inherent risks involved in the industry, like working with complex machinery and hazardous materials. Adhering to ISO 45001 helps you achieve a safer workplace, protect employees, and sustain operational efficiency.
How to improve aerospace product development and manufacturing
To stay competitive and meet the demanding standards of the aerospace industry, manufacturers must continuously refine their processes. Here are four strategies that can help you improve:
1. Implement advanced manufacturing technologies
Manufacturing technology has seen remarkable advancements in the past few years, and the aerospace industry has much to gain from adopting those advancements. Here are three technologies to consider implementing in your aerospace manufacturing process:
- Digital twins: Digital twins are virtual replicas of physical assets that simulate their real-world counterparts in a digital environment. Using digital twins, aerospace manufacturers can monitor the performance of components and systems in real time. As a result, you can optimize production processes, detect issues early, and perform predictive maintenance. These benefits improve your efficiency and reduce downtime.
- Additive manufacturing: Also known as 3D printing, additive manufacturing allows you to create complex, customized aerospace parts with high precision. This technology supports rapid prototyping so you can speed up your design and testing processes. It also reduces material waste and helps you produce parts that are both strong and lightweight — a crucial balance to strike in the aerospace industry.
- Advanced robotics and AI: Robotics have become a cornerstone of the manufacturing industry due to their ability to perform repetitive tasks with high efficiency. For example, you can use robotic technologies instead of human labor for tasks like welding and assembly. Artificial intelligence (AI) complements robotics by analyzing vast amounts of data to optimize processes, provide real-time feedback, and automatically adjust operations to suit evolving production needs.
2. Adopt lean manufacturing principles
Lean manufacturing optimizes production processes by eliminating waste and downtime, focusing only on the activities that provide the most value. This helps you cut costs and deliver products at a better price. Lean manufacturing principles can apply to any manufacturing process, but in the aerospace industry, they’re particularly effective when combined with job shop manufacturing.
With job shop manufacturing, you produce small batches of products to fulfill custom jobs. This approach allows you to efficiently handle complex, one-of-a-kind orders and adapt to specific customer requirements — ideal for the aerospace industry, where you frequently deal with specialized components and intricate designs. Implementing the job shop approach and other lean manufacturing principles streamlines workflows and reduces excess inventory.
3. Invest in continuous training and development
A prepared workforce is a productive workforce. At every stage of product manufacturing, you want employees to apply their skills and expertise with precision and adhere to safety protocols, and that requires training. Get employees up to date on the latest technologies, techniques, and regulatory requirements by investing in continuous development.
Regular training programs should focus on technical skills, like operating advanced machinery, as well as soft skills like problem-solving and teamwork. Additionally, providing training on safety protocols and industry standards helps you prevent accidents and maintain compliance.
4. Enhance collaboration and communication
To create complex aerospace parts efficiently, your production process must be cohesive. This requires collaboration and communication across all stages of the supply chain, from raw material suppliers to component manufacturers and assembly teams.
One way to strengthen this aspect of your performance is with supplier relationship management (SRM). SRM techniques focus on building and maintaining strong partnerships with suppliers, ensuring that all parties work toward common goals and standards.
The right inventory management software also enhances collaboration and communication. Production line employees need real-time access to accurate inventory data so they can synchronize their work and reduce bottlenecks. Fishbowl Advanced provides this real-time visibility and lets you control user access permissions.
Take your manufacturing process to new heights with Fishbowl
Need help optimizing your aerospace parts manufacturing process? Let Fishbowl be your co-pilot.
With Fishbowl Manufacturing, you can streamline operations, maintain precise inventory control, and ensure regulatory compliance. Plus, Fishbowl’s software seamlessly integrates with QuickBooks, making it easier to manage your company’s finances.
Discover how Fishbowl helps you keep operations running smoothly. Book a demo today.