My insights from AeroDef 2017: The Real Cost-of-Poor-Quality (CoPQ) Part I

About Plataine

Brought by Plataine, a leading provider of AI agents for advanced manufacturing. Plataine’s AI agents optimize planning and scheduling, material management, and supply chain collaboration.
Learn more or check your fit for AI based planning and scheduling.

I’ve been thinking for quite a while about the real cost of poor quality and the impact of discovering manufacturing faults too late in the process.

This year at AeroDef I had the privilege to take part in a panel discussion about “Industrial IoT and the Digital Twin” and discussed it with many manufacturing executives within the Aerospace and Defense, as well as other verticals. It appears that this topic is on many managers’ minds so here are some insights:

Quality issues happen

A Senior VP of Operations of a leading aero-structure company just mentioned to me: “Quality issues happen, but they quickly evolve into much bigger problems if not handled while still small.” We regularly hear about parts, that have made it through the entire (or almost entire) production process, only to be discovered then as having expired or defective material in a quality inspection.

Faulty material batch – the “recall” scenario

Another scenario that came up at the conference is when a supplier reports a faulty batch of material or components and that’s when chaos starts. How quickly can you identify all parts, assemblies and kits that were produced out of this batch? Would you stop production and get your staff to go through paper work and route cards until all parts are collected? What would be the impact over your week’s throughput and your ability to deliver customer orders on time?

Disrupting your manufacturing schedule

I keep hearing that many of the processes and machines are built and designed to handle several kits or a specific batch at a time, or per cycle. When you detect a defective part just before it needs to go to the next station, for example, an autoclave curing, this can throw your manufacturing schedule off course, leading to bottlenecks and delays.

A problem found early is a problem solved

During our discussions, we all agreed that in order to reduce the cost of poor quality we need to identify the problem at an early stage. As a Head of Quality once told me “A problem found early is a problem solved”.

In part II of this post I’ll be sharing the solutions to these issues discussed during the panel and the entire discussion around IoT technologies and the Digital Twin. Stay tuned..

Author: Avner Ben-Bassat, CEO & President of Plataine
Don't miss new updates on your email
Your email will be handled as detailed in our Privacy Policy

Why Conversational AI Alone Won’t Transform Manufacturing

Over the past two years, almost every software conversation has started sounding identical: “AI-powered,” “Copilot,” “Chat with your data,” and “Ask your system anything.”
At first, it felt revolutionary. Suddenly, enterprise software could respond conversationally, summarize information, generate reports, and interact using natural language. Across industries, organizations rushed to integrate generative AI into their products and workflows.
But recently, something interesting has started to happen. The conversation around industrial AI is beginning to mature.
The market is moving beyond the idea that conversational interfaces alone are enough to drive a digital transformation. The real focus is shifting toward something much bigger: autonomous AI agents that can orchestrate actions, automate decisions, and operate directly within complex business processes.
That shift matters enormously for the industrial sector. Because manufacturing has never really struggled with conversations.
It struggles with decisions.

Read More >

Beyond the spreadsheet: 5 Ways Agentic AI is Rewiring the Factory Floor

Spend enough time walking factory floors and sitting side-by-side with planners, and you start to notice a pattern that repeats itself almost everywhere.
The systems are there. The data is there. In many cases, there’s a lot of both.
But when it comes to actually making decisions, especially around scheduling, it still comes down to manual effort, experience, and a fair amount of workaround thinking.
That’s the paradox of modern planning and scheduling.
Over the years, manufacturing has gradually introduced more digital systems into the production environment. But in many factories, paper travelers, printed schedules, whiteboards, spreadsheets, and manually distributed plans are still part of day-to-day operations. Even in highly advanced facilities, planners and operators often work across a mix of digital tools and manual processes to keep production moving. On the surface, there is more visibility than before, but much of the coordination still depends on people constantly connecting the dots themselves.But the reality on the ground often tells a different story.

Read More >

The Simplicity Advantage: What Manufacturing Can Learn from a 90s Mindset

Everything is getting more complex. So why are the smartest companies simplifying?
There’s something happening right now, and it goes beyond nostalgia.
From Carolyn Bessette-Kennedy to Calvin Klein, from interiors to the way people are starting to disconnect from constant noise, there’s a clear shift back toward simplicity. It’s reminiscent of the 90s, with cleaner lines, fewer distractions, and more intention in how we live and move through the day.
But this isn’t just about fashion or design. It’s not even really about nostalgia. It’s about clarity.
We’re living in a time where everything is faster, louder, and more demanding. Information is constant, and decisions are nonstop. As a result, there’s a growing realization that more isn’t always better. More inputs do not always lead to better outcomes. In many cases, they simply lead to more noise.
That is why simplicity is making a comeback, not as a trend, but as a response.

Read More >
Before you go….
Subscribe to our blog and be the first to get the latest trends!
Your email will be handled as detailed in our Privacy Policy