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For Whom the Alarm Tolls

Tuesday, October 14, 2025
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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.

Inadequate Systems & the Sounding Alarms

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.

Are you hearing any of these alarms?

  • Alarm bell

    You're running systems that are decades old—rigid, brittle, and expensive to change.

  • Alarm bell

    You're reliant on "modern" tools – Jira boards, collaborative spreadsheets, home-grown apps—stretched far beyond what they can or should do.

  • Alarm bell

    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.

Startup Alarms

Here are some of the serious problems that show up much earlier than startup leaders expect:

  • Alarm bell

    "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.

  • Alarm bell

    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.

  • Alarm bell

    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.

  • Alarm bell

    Velocity without visibility: Weekly design pivots outpace document control; test systems don't talk to build; actions don't block high-risk work.

What great startups learn early is that speed and safety share the same circuit.

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:

  • One backbone, many roles: Operators, engineers, suppliers - all on the same single tool.
  • Built-in control, not after-the-fact audits: Actions and approvals enforce the next right step by default. You shouldn't have to dig through the database history to understand the narrative and story of your hardware.
  • Trace by design: Parts, pedigree, revisions, and results are born connected, not reconciled later.
  • Change as a feature: Off-nominal work, ECOs/ECNs, and test feedback flow forward instantly with uncompromising control and authorized flexibility when needed.
  • Quality everywhere: Not a department, not "in the QMS", but an attribute of every transaction.

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.

System Patches May Quiet the Alarm, But Not Reduce the Risk

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:

  • Warning Legacy MES/ERP - Rigid dinosaurs. High complexity. Absurdly painful UX. Finance-first, not factory-first. ***Cough cough… SAP, Costpoint, Siemens.
  • Warning Point solutions - The so-called Factory OS that promises flexibility usually delivers chaos. Without enforced process, trace and control vanish. At scale, "do anything" turns into "no one knows what happened."
  • Warning Single-domain systems - A procedure platform might be elegant for test execution, like say an AI-Powered Process and Resource Management System for Complex Operations, but what's the backbone? If test is the brain, planning, production, quality, and suppliers need the spine. Starting without it makes no sense.
  • Warning Homegrown workarounds - Jira hacks, spreadsheets, half-built apps stretched by overworked teams. Band-Aids, not nervous systems.

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.

What Integrated Quality Looks Like

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:

  • Quality shows up everywhere in your workflow. Trace is law & controls are not absent or optional or mutable but ubiquitous with authorized flexibility so speed is not sacrificed.
  • All actions are connected. An operator calling an inspector does so in a system where the action is connected, enforced, and visible.
  • Dispositions don't need babysitting. The engineer authoring a change sees its impact cascade to supply chain, shop floor, and test in real time.
  • Pedigree works. Yeah, like really works - your workflows yield and adapt based on rigor and usage needs.
  • Data that acts. A failed data collection means something and does something - an automated nonconformance allows work to continue when appropriate with fire & forget controls in place downstream.
  • Systemic containment. Manufacturing engineers are prompted to think about the nature of a defect's cause before dispositioning the individual instance, and flagging a suspect systemic defect drives integrated containment and connects root cause analysis and corrective actions.

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.

Fragmented vs. Integrated Quality

Before: Fragmented System

After: Integrated Nervous System

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.

A True Digital Thread Triggers Actions and Output

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.

True Digital Thread

Nervous System Infographic

Digitally Connected Workers

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:

Icon Worker

Operators

Operators no longer waiting or second-guessing. Every action tied to process, enforced automatically, documented without effort or friction.

Icon Engineer

Engineers

Engineers no longer reconciling six systems. Change requests ripple across design, build, test, and operations - in seconds.

Icon Leader

Leaders

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.

Icon Supplier

Suppliers

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:

  • Arrow Speed Without Fear: You can launch in half the time - not by cutting corners, but by building the right corners into the system.
  • Arrow Agility Without Chaos: Off-nominal work, supplier shortages, unexpected rework - planned and executed without breaking approvals.
  • Arrow Learning Without Blame: Every nonconformance becomes a teacher. Containment, corrective, and preventive actions live in one chain, feeding back into your organization.

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.

What Quality Done Right Looks Like… And Sounds Like

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:

  • Every bolt, every fastener, every assembly operation tied to live interconnected digital records. No missing data, no "oops I forgot" repairs.
  • Engineers, operators, inspectors working within one frame: nonconformances trigger corrective actions automatically; revisions propagate without "configuration control" ambiguity and chaos.
  • A legacy system where data latency, manual handoffs, and untraceable changes are eliminated. Imagine no more where-did-this-go silos, no more "spreadsheets that no one trusts," no more "we'll fix it next audit."

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.

How the Bolt Remove & Replace Should Have Happened

#

Step

What Happened in Real Life

How It Would Work with Embedded Quality

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.

Quality Embedded: The New Standard for Manufacturers

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:

  • End-to-end traceability: Every part, revision, inspection, action and workflow is connected upstream and downstream to all connected workers.
  • Built-in discipline: The system enforces good process. No bolt is replaced, no change is made, without visibility and accountability.
  • Quality as a partner in speed: Not a gate at the end, but embedded throughout development and production and operation.
  • Learning loops instead of firefighting: Errors don't just get closed - they teach. Systemic defects get addressed at the root cause.
The Illusion of "Modern" and "Flexible"

Many executives believe: "We've upgraded our MES, ERP, or adopted new modern cloud solutions, so we're good."

But here’s the rub: 

  • Modern doesn’t mean integrated. 
  • Cloud-based does not inherently mean reliable, traceable, controllable, or flexible in the way you need to run your business. 
  • Flawed flexibility and attribute based databases and workflows without appropriate guardrails = risk and eventual failure.

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?”

A System to Silence the Alarms

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:

  • Time Icon Complexity is exploding: new space, new defense, aerospace, clean energy, hypersonic systems, ultra-high precision components and integrated assemblies.
  • Time Icon Speed is non-negotiable and change (concurrent engineering) is inevitable. Time-to-market, regulatory approval cycles, global competition.
  • Time Icon Risk tolerance is nearly zero. A single escape - safety, compliance, or product failure - can kill you.

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.

  • Arrow You might survive, but you won't lead.
  • Arrow You might build, but you won't pioneer.
  • Arrow And you'll be vulnerable when the unexpected happens (and it always does).

Why Manufacturo Is Not Just Another MES

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:

  • A single integrated solution: production, quality, inventory management, nonconformance, document control, integration management, traceability - all built natively, not stitched. Not an afterthought. It's always been the foundation.
  • Designed for high complexity, high regulation, high risk industries and products: space, aerospace, hypersonic flight, clean energy, precision supercars, autonomous aviation and vehicles, to name a few.
  • Usability first: operators, engineers, supervisors, compliance teams all get tools that help them do the right thing - without fighting the system.
  • Real-time visibility, accountability, and the ability to lock in processes: nothing "slides through" because it was inconvenient.
  • Speed and safety: go fast without sacrificing control and information integrity.

Why We Do What We Do


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.

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