Ignition-Powered UNS Establishes Single Source Of Truth For Aerospace Manufacturer

Project Overview

BMT Aerospace is modernizing its factories for the Fourth Industrial Revolution by combining centralized data collection with innovative software solutions to improve quality and efficiency. With the help of AT-Automation, BMT Aerospace implemented an Industrial Internet of Things (IIoT)-connected Manufacturing Execution System (MES) with a database structured as a Unified Namespace (UNS), establishing a single source of truth across the organization.

Challenges

What started as a small innovation initiative quickly grew into a company-wide digital transformation strategy.

• Heterogeneous environment: Over 70 brands of machines and equipment needed to be integrated into one system.
• Data silos: Shop floor data was fragmented, limiting visibility and slowing decision-making.
• System evolution: The company needed to replace its legacy MES and support a new ERP system while avoiding disruption to operations.

BMT Aerospace’s vision was clear: create a robust, scalable platform that would not only capture machine and operator data but also contextualize it for company-wide use.

Solution

AT-Automation deployed Ignition as the backbone of a complete data ecosystem.

• Machine PLC connectivity: Ignition connects directly to PLCs across 70+ machine/CNC brands via native and custom drivers—standardizing tags into the UNS and enabling secure monitoring and, where permitted, control.
• Edge connectivity: Ignition Edge and Beckhoff IPCs connect legacy and restricted machines with near plug-and-play sensor onboarding and centralized configuration.
• New MES in Ignition: A custom MES layer was developed entirely within Ignition. It integrates seamlessly with the UNS and ERP system, capturing operator input, managing production workflows, and adding context to raw IIoT data.
• Unified Namespace: A central Ignition server aggregated data into a UNS, ensuring every stakeholder could access consistent, contextualized information.
• Scalable architecture: Data flowed seamlessly through MQTT into Canary for historical storage and visualization via Axiom.

This architecture created a living, real-time digital twin of BMT Aerospace’s factories, accessible to operators, engineers, and management alike.

Ignition is now a central component of the entire system, playing a pivotal role in both data acquisition and visualization with a full suite of interface options.

Result

The new system immediately reduced paperwork, streamlined reporting, and gave every stakeholder access to trusted, real-time data.

During testing, engineers used Axiom dashboards to uncover a hidden inefficiency: one drilling step was cutting air instead of metal. By adjusting the process, production time for that task dropped by 25%.

This was just the beginning. As more users get access to the UNS, BMT Aerospace expects ongoing efficiency gains, predictive insights, and eventually, fully adaptable shop floor operations.

Further optimizations and benefits are expected to emerge as more systems and users adopt the new UNS structure. BMT Aerospace is aware that the road to innovation and industry 4.0 has six steps:

1. Computerization – Going Paperless
With SAP and Windchill, BMT Aerospace is digitizing documents and transactions, moving away from paper-based processes. This foundation ensures that every record, drawing, and transaction is available digitally and consistently across the organization.

2. Connectivity – Capturing Data from Machines and People
True Industry 4.0 requires rich, contextualized data. PLC connectivity ensures that machines are fully monitored, while the new MES captures operator input. Additional edge PLCs enable the deployment of extra sensors, giving a complete view of production conditions.

3. Visualization – Building a Digital Twin
Once data is flowing, BMT Aerospace is creating a digital twin of the factory. This real-time model is automatically updated using live data, so the company always knows exactly what is happening on the shop floor and can simulate improvements before making changes in production.

4. Transparency – Turning Data into Insight
With the help of analytics, patterns, and AI, raw data becomes meaningful information. Early applications include clustering, pattern recognition, and anomaly detection—giving operators and managers clarity on where bottlenecks or quality risks may arise.

5. Predictability – Forecasting Performance
As more data is captured and analyzed, predictive capabilities come into play. BMT Aerospace will be able to anticipate machine behavior, maintenance needs, and production outcomes—minimizing downtime and optimizing scheduling.

6. Adaptability – Closing the Loop
In the final stage, the factory becomes self-optimizing. Instead of just informing operators and managers, the system can take action, automatically adjusting processes in real time to improve efficiency, quality, and flexibility in a rapidly changing environment.

The early steps; such as implementing SAP, Windchill, MES, and IIoT; require significant investment and may not yield immediate financial returns. However, these investments are strategic enablers. By laying this foundation now, BMT Aerospace is positioning itself to unlock exponential ROI in the later stages, where predictive analytics and autonomous decision-making will drive productivity, agility, and competitive advantage.

Start Date: December 2023

Deploy Date: January 2025