Aerospace

Industrielle Leistungsfähigkeit für die geplante Rate.

Johannes Seeberger

B.Eng.

Your Contact Person

Aerospace unter Wachstumsdruck

Wachstum braucht industrielle Reife

Hohe Auftragsbestände, beschleunigte Großprojekte und neue Raumfahrtunternehmen erhöhen den Druck auf Produktionssysteme und Lieferketten. Komplexe Produkte, lange Durchlaufzeiten, knappe qualifizierte Quellen und begrenzte Kapazitäten treffen auf hohe Anforderungen an Qualität und Nachweisführung. Entscheidend ist, industrielle Reife, Lieferfähigkeit und Produktionsleistung so abzusichern, dass zusätzliche Umfänge zuverlässig erreicht werden.

roeren in der Luft- und Raumfahrt

Industry experience that makes a difference in implementation

The product and prototype function flawlessly from a technical standpoint; however, for mass production, there is a lack of coordinated processes, equipment, material procurement, and maturity in terms of quality, the supply chain, and organization. The goal is a production system that enables the reliable delivery of the required quantities.

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Assess production readiness across product, process, quality, supply chain, and organization, and identify critical gaps in readiness

Ensure that product design is suitable for manufacturing and define manufacturing processes, work sequences, and realistic target times

Develop workstation, production line, and assembly concepts—including production pacing, material provision, and ergonomics—and establish standards, work plans, and manufacturing documentation

Specify concepts for equipment, fixtures, tools, and test equipment—including specifications—and provide technical support for procurement, implementation, and commissioning

Develop an industrialization roadmap that includes maturity levels and go/no-go criteria, and manage pilot builds and validation under near-production conditions

Ensure method implementation and traceability, and manage configuration and change management during the transition to series production
Scarce resources, long-lead-time parts, insufficient capacity, or inadequate industrialization among suppliers jeopardize production targets. It is crucial to ensure transparency regarding risks and performance capabilities and to develop critical suppliers until a stable supply is achieved.

related services

Prioritize critical components and suppliers, and assess local capacity and industrial maturity

Determine, validate, and verify capacity and investment requirements based on the target rate

Structuring Sourcing Roadmaps, RFQ Packages, and Qualification Logic

Develop secondary sources and reclassify displaced volumes

Ensure transparency regarding supplier tiers, procurement lead times, and obsolescence, as well as demand, inventory, turnover, and open orders in critical situations

Prioritize critical orders, ensure delivery and shipping schedules, and operationally manage supplier development until production reaches a stable level
The planned production rate is increasing, but actual output is not keeping pace reliably. Lack of capacity, unbalanced workloads, bottlenecks, or a control system that fails to keep up with the ramp-up jeopardize rate gates and delivery commitments. It is crucial to translate demand into a robust production system and to operationally secure each milestone all the way to the proven, stable target rate.

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Translate target rates into capacity, staffing, space, and resource requirements

Align production line, station, and assembly concepts with the target rate

Identify and resolve bottlenecks and limiting work tasks

Systematically assess readiness before each milestone

Establish ramp-up metrics and daily performance management

Adjust measures until a stable target rate is achieved
Once production is underway, consistent quality, capacity, and process performance determine whether the planned output rate can be sustained over the long term. Scrap, rework, recurring defects, unstable special processes, or acute escalations tie up resources and can even lead to the threat of a line stoppage. In such cases, the root causes and bottlenecks must be quickly identified, and the relevant technical and operational measures must be implemented until stable performance is restored.

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Analyze rejects, rework, held-up inventory, and recurring defects; systematically identify the causes and eliminate them permanently

Increase Yield by Improving Quality in the First Run

Stabilize special processes and the associated documentation; address audit findings; and confirm the effectiveness of corrective actions

In critical situations, quickly mobilize task force teams on site and establish a reliable picture of the facts

Analyze bottlenecks, capacity, and yield, and adjust the process, staffing, and inspection logic to achieve the required performance

Establish shop floor and performance management, and incorporate response plans and escalation thresholds into routine operations
High-quality components should be used for longer or returned to the supply chain. At the same time, technical, regulatory, and certification requirements in the aerospace industry are particularly stringent. For remanufacturing to be viable, technical feasibility, process design, manufacturing costs, suppliers, and industrialization must all align through the certification process.

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Evaluate the technical reusability of components

Design remanufacturing processes and derive technical requirements

Determining the Production Costs and Business Case for Remanufacturing

Identify suppliers, evaluate their technical qualifications, and support the awarding of contracts

Implement the operating system and industrialization in collaboration with suppliers

Support first-article, validation, and approval processes through to implementation

International Project Experience

EMEA

Germany

A Structured Introduction

Understand the situation on the ground. Secure the rate. Demonstrate stability.

When production targets, delivery capabilities, or industrialization come under pressure, we go directly to the production floor and review relevant supplier processes. We combine our on-site observations with data on maturity, capacity, output, quality, and inventory to identify the rate-limiting bottleneck and immediately derive concrete actions from it.

Our Process

Assessing Target Rates and the Need for Action

We determine which rates, milestones, or delivery commitments must be met and whether the issue involves a situational escalation, a fundamental ramp-up challenge, or a need for structural industrialization.

Understanding the Local Production System and Supply Chain

We work in manufacturing areas and relevant supplier processes, and organize work sequences, equipment, material flow, quality requirements, and interfaces within a real-world context.

Clarify Maturity, Bottlenecks, and Measures

We combine maturity levels and process maps with key metrics on output, capacity, inventory, and quality to identify the rate-limiting bottleneck and prioritize actions. In critical situations, we immediately switch to task force mode or operational ramp-up management.

Case Study: The Aerospace Industry—Between Growth Momentum and Capacity Pressures

~ 0 Years

Production Capacity

corresponds to the global order backlog for aircraft at current capacity levels.

70– 0 / month

A320 Family aircraft

Airbus plans to produce this many per month by the end of 2027—after which the production rate is expected to stabilize at 75.

≥ 0

There is a shortage of airplanes

cumulatively compared to the originally expected shipments.

0 billion euros

on defense spending

The EU-27 reached this figure in 2025—20% more than in 2024.

0 billion euros

Public Space Budgets

European countries reached this figure in 2025—an increase of 12%.

0 Years

the average age was

the global aircraft fleet in 2025.

Sources: IATA, Aerospace Supply Chain Bottlenecks (2025); Airbus, Half-Year 2026 Results; European Defense Agency, Defense Data 2025–2026; ESA, Space Economy Report 2026. Compiled by the author.

Aerospace

Aerospace unter Wachstumsdruck

Wachstum braucht industrielle Reife

roeren in der Luft- und Raumfahrt

Industry experience that makes a difference in implementation

International Project Experience

A Structured Introduction

Understand the situation on the ground. Secure the rate. Demonstrate stability.

Our Process

Assessing Target Rates and the Need for Action

Understanding the Local Production System and Supply Chain

Clarify Maturity, Bottlenecks, and Measures

Let's talk about the challenges you're facing.

Industry Network

Contact

Aerospace

Aerospace unter Wachstumsdruck

Wachstum braucht industrielle Reife

roeren in der Luft- und Raumfahrt

Industry experience that makes a difference in implementation

Bringing a Product and Production System to Mass Production Readiness

Ensuring Supply Capacity and Identifying Critical Suppliers

Ramp up and achieve the target rate in a stable manner

Stabilize Quality and Production Performance

Industrializing Recycling from a Technical and Economic Perspective

International Project Experience

A Structured Introduction

Understand the situation on the ground. Secure the rate. Demonstrate stability.

Our Process

Assessing Target Rates and the Need for Action

Understanding the Local Production System and Supply Chain

Clarify Maturity, Bottlenecks, and Measures

Let's talk about the challenges you're facing.

Industry Network

Contact