Bespoke Solutions Manufacturing Case

Beyond the Mainframe: How a Bespoke AI Solution Prevented $2.8M in Recalls for an Aerospace Leader

A Tier-1 aerospace supplier was trapped by its own success, constrained by proprietary quality control processes running on 30-year-old legacy mainframe systems. This outdated infrastructure made it impossible to innovate; critical sensor and quality data were locked in silos, and production teams relied on inefficient paper-based processes. With their unique quality methods, off-the-shelf Manufacturing Execution Systems (MES) from providers like Rockwell Automation or Siemens were not a viable option.

Developing custom AI models trained on historical sensor data to predict component quality and forecast potential equipment failures.

Building a new, web-based quality management application from scratch using a .NET and React stack to replace the legacy green-screen interface with an intuitive dashboard.

Creating AI-powered mobile applications for tablets, featuring on-device AI using Core ML for offline functionality, delivering real-time recommendations to technicians on the factory floor.

The integrated solution delivered transformative, measurable results across the board, moving the client from a reactive to a predictive operational model.

$2.8M in Recalls Prevented:

By identifying potential defects early, the system has already prevented extremely costly and reputation-damaging recalls.

18% Improvement in OEE:

Predictive maintenance alerts from the AI models have drastically reduced unplanned downtime, directly boosting Overall Equipment Effectiveness.

95% AI-Powered Quality Detection Accuracy:

The custom models achieved near-perfect accuracy in predicting quality issues before they became major problems.