By Innovative Measurement Solutions • November 12th, 2025
Aerospace manufacturing demands extreme precision. One of the biggest hidden costs in the industry is rework, or fixing or remachining parts that don't fit or line correctly during assembly.
The problem? Rework is not just costly. There is a risk of noncompliance, projects are delayed, and providers' reputations are damaged. Actually, up to 30% of production expenses can be attributed to quality issues and rework, an amount that aerospace companies cannot afford.
So how can aerospace manufacturers reduce rework and ensure first-time correct assembly? The answer lies in predictive fit-up analysis.
Every misalignment affects the production process as a whole:
Financial Impact: Remaking precise aviation parts can cost tens of thousands of dollars.
Schedule Delays: Missed days (or weeks) on the production line have an effect on delivery timelines.
Compliance Risks: The variability offered by rework makes it more challenging to meet strict aerospace quality standards.
Reputation Damage: Supplier evaluations and client trust are negatively impacted by missed deadlines.
Rework is not only a headache, but it also kills earnings.
The majority of aerospace quality control relies on inspection following assembly or machining since mistakes are discovered too late.
Downtime results from adjustments.
Rework may be required for entire assemblies.
By then, the effects on time and money are inevitable. Before assemblies are made, manufacturers need a mechanism to verify them.
At IMS, we use predictive fit-up analysis to assist aircraft manufacturers in minimizing rework. We employ sophisticated metrology tools and simulation to: Digitally Validate Fit-Up → Simulate how parts will align before production, rather than waiting for components to break during assembly.
Identify Conflicts Early Identify interference, gaps, and misalignments before they become expensive.
Encourage First-Time Correct Builds ↑ Make sure assemblies line up correctly the first time.
Save Time and Money → Cut down on scrap, downtime, and wasted materials.
Quality control becomes proactive instead of reactive with this predictive method.
One aerospace client lost weeks of production as a result of repeated misalignments during the assembly of large components. Because each fix required revision, certification timelines were postponed.
The client saw a 40% reduction in alignment time with FL-IMS and predictive fit-up study.
Eliminating unanticipated rework from final assemblies
Met the strict requirements for aeronautical compliance and was delivered on time.
We know more than just what can be seen. FL-IMS combines advanced technologies with predictive solutions, including: Part Fit-Up Analysis and Forecasting
3D Laser Scanning and Modeling
Load Path Interference Measurement
Precise Alignment
This means that in addition to measuring parts, airplane makers also construct first-time-right assemblies and forecast results.
Although rework can seem like a standard procedure in the aerospace industry, it doesn't have to be. Manufacturers may reduce hidden rework costs, deliver projects on time, confidently meet regulatory standards, and safeguard their brand with first-time-right builds by employing predictive fit-up analysis.
Your aerospace projects should not be depleted by rework. Make an appointment with FL-IMS right now.