From the Roads to the Skies: The Surprising Collaboration Reshaping Aviation

The automotive sector excels in mass production techniques, supply chain optimization, and operational efficiency, making it an ideal source of inspiration for the aviation industry. The cross-pollination of expertise between these two sectors is becoming increasingly evident, with several aviation companies collaborating with automotive giants to improve their manufacturing processes. 

Cross-Industry Partnerships 

Partnerships between aviation and automotive companies are proving to be a significant shift in the industry. One of the most notable examples is the partnership between Joby Aviation and Toyota. Joby Aviation, a leading company in electric vertical take-off and landing (eVTOL), has acquired a facility at Dayton International Airport to support its initial manufacturing operations (Archer). 

By leveraging Toyota's expertise in areas like supply chain management, lean manufacturing, and quality control, Joby aims to improve scalability and overcome efficiency challenges faster. Suppliers like Banner Metals Group already seamlessly integrate into complex supply chains and provide customized manufacturing solutions, keeping aviation projects operating on schedule. 

Ramping Up Production Volumes 

One key lesson from the automotive world is the ability to scale production volumes rapidly. Archer, another eVTOL aircraft manufacturer, has recognized this potential. Teaming up with Stellantis, a global automotive giant, Archer is building a high-volume manufacturing facility in Georgia designed to produce up to 650 aircraft annually (Joby Aviation, Inc.). 

Adopting automotive-inspired mass production techniques, such as streamlined assembly lines, standardized processes, and automation, makes this extraordinary production rate possible in the aviation industry. 

Risk Mitigation and Strategic Sourcing 

Archer's strategic sourcing strategy is noteworthy, as approximately 80% of the components and subsystems for their Midnight aircraft are sourced from leading aerospace suppliers with certification heritage (Archer). This approach significantly reduces certification risk, as these components have already been certified for use in other aircraft or are derived from previously certified designs. 

Rapid Prototyping and Testing 

The aviation industry can also benefit from the automotive sector's rapid prototyping and testing expertise. Archer's integrated test lab and manufacturing facilities in San Jose, California, support the assembly of conforming aircraft for piloted "for credit" testing with the Federal Aviation Administration (FAA) (Archer). This approach, akin to automotive testing and validation processes, enables efficient identification and resolution of issues before full-scale production. 

Capital Efficiency and Phased Approach 

Archer's strategy of minimizing capital expenditures before generating significant revenue from operations is another valuable lesson from the automotive industry. By adopting a phased approach to bringing on Stellantis as a contract manufacturer, Archer aims to gradually absorb the capital requirements related to manufacturing ramp-up and working capital, ensuring capital efficiency. (Archer) 

At Banner Metals Group, we understand the importance of capital efficiency. We can work closely with aviation manufacturers to develop cost-effective solutions that support their phased approach to scaling up production. 

By embracing practices from the automotive manufacturing sector, the aviation industry can unlock new productivity levels, cost-effectiveness, and scalability. Cross-industry collaborations, strategic sourcing, rapid prototyping, and capital-efficient approaches are just a few examples of how the aviation sector can benefit from the expertise of automotive giants.  

Banner Metals Group stands ready to contribute as a trusted supplier and partner. Our expertise in lean manufacturing, supply chain agility, quality assurance, and customized manufacturing solutions can support the development of efficient and scalable production processes for aviation components and systems. We can play a vital role in revolutionizing the aviation manufacturing landscape by fostering cross-industry collaborations and knowledge transfer. 

References 

Archer. "Q4 & FY 2023 Shareholder Letter." 2024. 

Joby Aviation, Inc. "BusinessWire." 05 March 2024. Joby Acquires Facility in Ohio, Begins Hiring to Support Initial Manufacturing Operations.