Author
Zane Shewalter
Chief Customer Experience Officer (CXO) at Manufacturo
You chose the window seat. One moment, you’re enjoying the view. The next your shirt is ripped off and sucked into the sky and you're gripping your seat for dear life while staring in shock through a gapping, vacuous hole in the aircraft.
The view isn’t so great anymore.
Sadly, this isn’t fiction. This was a real life event.
You may recall the incident. It was January 2024. A commercial aircraft took off out of Portland. Soon after, a door-plug, a piece of fuselage naturally meant to stay in place, blew right off the plane during flight.
How did it happen?
Processes and digital solutions failed to control a mandatory remove & replace transaction on a rework disposition.
Four bolts had been removed and never replaced during a repair in the factory. But there was no documentation. No follow-through.
Miraculously, no lives were lost. But the warning about insufficient manufacturing systems was deafening.
Stories like the door-plug aren’t aberrations; they’re signals.
Too many high-stakes manufacturers continue to run on desperate, duct-taped solutions. These patched-together systems and legacy approaches are sounding off blaring warnings that may not be near fatal, mid-air incidents, but these alarms should have us sitting at rapt attention.
You're running systems that are decades old—rigid, brittle, and expensive to change.
You're reliant on "modern" tools – Jira boards, collaborative spreadsheets, home-grown apps—stretched far beyond what they can or should do.
Your MES, ERP, and QMS live in parallel universes. Data hides in silos until something important needs it—and it isn't there. Or worse, it is there and you didn't know about it.
Yes, it's true that the consequences of these situations aren't usually a nearly-fatal catastrophe, but they drag on productivity and efficiency before they threaten lives. Think, missed schedules, rising rework, defects escaping into the field, regulatory drag, and reputational damage that takes years to unwind.
And yes, startups have these alarms going off too. It's not just bigger companies that hear them. In fact, startups hear them sooner as they scale at speed.
Here are some of the serious problems that show up much earlier than startup leaders expect:
"We'll fix it later" debt: Notion checklists, nonconformance Jira and ticketing system hacks, and spreadsheet BOMs feel fast—until they become your operating system by accident. Vital technical and engineering information stacks up in these unstructured databases and becomes abstracted and unusable.
Flexibility without structure: A "do anything" database bends early… then snaps under load when you need it the most. Jumping into one of the new "modern" flexible solutions offering you extreme flexibility sounds great at first, but then you'll soon be talking with people like us to untangle the mess and migrate you into a scalable structure with control and safety built in.
Shadow data ≠ single source of truth: Google Drive versions, Slack approvals, ad-hoc test logs—none of it connects when the first customer or external audit arrives or you need to actually learn from your data. Let alone if you need to investigate a real anomaly.
Velocity without visibility: Weekly design pivots outpace document control; test systems don't talk to build; actions don't block high-risk work.
Great startups will embed an operating nervous system from Day 1.
In this way, one thread ties design, source, build, test, quality, and suppliers together. The set-up done right, moving fast is then safe and reliable; it doesn't require rework, heroics, or luck.
It inherently builds the 'test like you fly' mentality and approach into every workflow." If you don't, it's not a valid test.
Here's the physicality (if you will) of a smart startup's operating nervous system:
The net effect is preserving the startup's superpower - that is, learning and iterating fast - without transforming your admirable creation into a hideous Frankenstack, one that you'll have to spend your Series B unwinding.
The industry is grabbing at solutions. Legacy tools drag you down and startup shortcuts create fragility, so what do companies grope for? Stopgaps.
These are patches that look like solution-based systems, but aren't. They fall short in too many key areas, effectively quieting the alarm, but not actually mitigating risk:
In these scenarios, too much remains disconnected. Disconnected workers, disconnected data, disconnected reality. To use the operational nervous system analogy again, here the backbone of operations can't feel the other body parts - what are the hands doing? The feet? The right middle finger?
Manufacturo integrates cross-domain workflows and embeds quality as a core foundational competency. We're not bolting on modules after the fact to catch up, and we're not building unstructured and unsustainable flexibility and mutable "attribute" based data that we know you'll regret later.
Everyone says, "We care about quality." And they honestly do. But quality in isolation is just another silo.
The litmus test for true quality is when things like the following are commonplace:
When all of the above is in place, that is when quality becomes a part of the nervous system of the factory. No longer is quality just a box to check or another thing to manage in yet another disparate system.
When fully embedded, quality signals to the factory when to sprint, when to recover, and when to stop before breaking.
Legacy MES + spreadsheets
Single connected backbone
Disconnected approvals
Actions enforced in-line
Manual reconciliation
Trace by design
Data silos
Live, unified data
Manufacturo delivers true integrated quality without sacrificing scale or speed with unprecedented capabilities - you'll know the difference when you see it.
Core to the digital nervous system is the digital thread. It’s like this: a digital thread tells you what happened; a nervous system decides what happens next.
Yet another issue undermining industry progress, output, and safety is that the digital thread in many cases isn’t an accurate source of truth. It’s not even a thread, more like tangled yarn.
But when you have a digital thread that is a single source of unambiguous truth, then the right decisions and next steps can flow confidently from it.
When a true digital thread connects an entire team, you get a digitally-connected workforce. In this situation your team can go fast safely with:
Operators no longer waiting or second-guessing. Every action tied to process, enforced automatically, documented without effort or friction.
Engineers no longer reconciling six systems. Change requests ripple across design, build, test, and operations - in seconds.
Leaders no longer flying blind. Real-time dashboards reveal not just what failed, but what's trending, what's about to fail, and what actions are preventing it.
Suppliers woven directly into the same thread. No more black holes at the edge of your factory.
What do we mean by go fast safely? Just as the name implies, it's when you can build and scale at speed without sacrificing compliance, safety, and control.
Go fast safely means:
Not only do you have the trust in your throughput, you gain confidence to move faster than your competitors. To make it clear, quality doesn't just produce positive compliance and safety outcomes, but advances productivity and innovation, too.
Like Forest once said, "Quality and productivity go together like peas and carrots."
Manufacturo has built a reliable, true digital thread. What's more, the digital thread runs through our operational nervous system and is live, enforced, and traceable, so the right action isn't suggested; it's the only thing that can happen. Thusly, accurate, real-time data is turned into enforced actions at line speed. The result is you build the right thing, and build the thing right.
A quality system embedded in operations and driven by a live digital thread works in quiet harmony.
You may feel uncomfortable with it at first. You've become so accustomed to the blaring alarms of systems that didn't work, after all.
This tranquil, quality-done-right workflow has:
On this humming factory floor, a door-plug with missing bolts would stand out. The repair would have been flagged. The risk mitigated. The headlines never made.
1
Bolts removed during rework
Remove-and-replace workflow automatically triggered
2
No record or verification
Mandatory buy-offs enforced
3
Aircraft released with missing bolts
Work blocked until verification complete
Here's how that door rework disposition would have worked using Manufacturo:
- Embedded disposition operations would have been triggered with planned remove and replacement components for the bolts
- Fully integrated mandated verification buyoffs would ensure the bolts were replaced and replaced correctly
- The replacement would have been guaranteed to occur at the right downstream step, because the nonconformance disposition constraints would be activated on both the door assembly and the vehicle level integrated assembly trace records ensuring work or events could not continue without the bolts being replaced until the nonconformance releases control.
- The defective bolts removed would be moved to an MRB cage on a related nonconformance with active constraints gating consumption to ensure they could not escape onto another airframe until the piece part dispositions take over. If the door-plug is moved or serviced in the future, the defects and the story sticks with the trace.
The door plug is the illustrative example of the depth of functionality a manufacturing platform must have with quality fully embedded into processes, and controlling and triggering workflows, to call it "Quality First."
To survive the shifts in the digital manufacturing space, and to grow past the competition, here's what leading manufacturers are doing:
Many executives believe: "We've upgraded our MES, ERP, or adopted new modern cloud solutions, so we're good."
But here’s the rub:
Flexible, modern tools are very frequently built at the cost of visibility, accountability, and systematic quality.
The question isn’t only, “Are my tools modern/updated?”
The question is also, “Does my solution (singular) enforce the right discipline, across all stakeholders, automatically, always? Does it enable flexibility correctly?”
Now is the time to upgrade to a modern system that balances flexibility and structure, and where quality is everywhere.
The urgency is clear. We are in an era where:
Legacy systems, patchwork disparate tools, and "close enough" flexible solutions aren't just slowing you down. They are exposing you to existential danger.
The "we've always done it this way" or the "I must have flexibility at all costs" mindsets are no longer justifiable.
We built Manufacturo because we saw what happens when companies patch around the edges or jump into the wrong "modern" of "flexible" solution.
We've been hearing all of the alarms going off from workarounds, spreadsheets, half-integrated apps, legacy MES upgrades, tools that don't talk to each other, Factory OS and AI-Powered Process & Resource Management for Complex Operations. It gives everyone in the industry a massive headache.
Here's how we silence the alarms, clear up the headaches, and help companies innovate and scale quickly and confidently. Manufacturo is:
We are one of you.
Our team helped design and scale one of the most influential factory operating systems of the last decade at SpaceX. We've seen what works when complexity climbs and the mission can't wait.
We want to share those decades of insights, working side-by-side with forward-thinking high-complexity manufacturers. Our approach is not just to build a system; it's to partner with our customers, solving problems and celebrating wins.
Plenty of smart folks are chasing the same goal of a better manufacturing system. But there's a difference between a checklist and a nervous system, between adapters and architecture, between builders and pioneers. That distinction matters. Your next choice matters.
We're here to help you make it.
Request a demo