Flexxbotics, the autonomous manufacturing platform leader, announced that Orizon Aerostructures (Orizon), an organically grown, vertically integrated, aerospace technology company manufacturing the largest, most complex structural components in the commercial aerospace, defense, and space markets, has deployed Flexxbotics to advance process trend intelligence, automated manufacturing compliance, and autonomous process control across its production operations.
Orizon is using Flexxbotics to enable greater manufacturing autonomy by connecting, mapping, and digitalizing critical factory assets with multi-source data from plant equipment, parts, automation, and tooling for autonomous process control. Multimodal data pipelines bring together CNC operating conditions – including spindle and axis servo loads – with robot joint loads and temperatures, probe measurements, and numerous other high-frequency production data streams. This contextualized data set feeds closed-loop process trend adjustments in Flexxbotics and is structured for Industrial AI training, validation, and inference.
“As we continue scaling precision production to meet the highest quality levels in aerospace manufacturing, data-driven autonomy is essential to empower our personnel,” said Rick Newell, Innovation Manager at Orizon Aerostructures. “Flexxbotics provides a single digital control plane which unifies our plant floor operations giving our teams real time feedback and closed-loop control which further improves uptime, quality, and capacity.”
The Flexxbotics deployment enables Orizon to proactively identify processing anomalies supporting reductions in rework and scrap of 40% or more using fewer resources. Improved utilization is achieved through a 25% decrease in unplanned downtime, providing greater overall efficiency and enabling 20% additional contract capacity.
“Flexxbotics makes our plant equipment interoperate for greater machine control, allowing our teams to set performance targets and automate adjustments that sustain tight tolerances,” said Rex Kelly, Manager of Program Management at Orizon Aerostructures. “The ability to reduce feed rates as loads increase and tie loads to individual tools and set limits is powerful and provides a foundation as we introduce greater levels of intelligence, automation, and networking into our operations to improve quality and provide affordability.”
Flexxbotics extends data capture from MODIG machines, FANUC robots, and IT business systems – including Infor PLM and QCS – to create an interoperable basis for deeper process visibility and continuous processing optimization updates. Together, these capabilities support autonomous manufacturing with process trend detection, automated manufacturing compliance, and controlled variable adjustments which further improve quality and increase uptime.
Founded in 2016 and headquartered in Kansas City, Orizon Aerostructures is an organically grown, vertically integrated, aerospace technology company manufacturing the largest, most complex structural components in the commercial aerospace, defense, and space markets. With a quality-first culture, Orizon combines decades of expertise, disruptive technologies, and state-of-the-art equipment across 850,000 sq. ft and over 900 associates. Orizon delivers precision manufacturing, specialty chemical processing, and large subassemblies to the most prestigious and demanding aerospace programs.
Flexxbotics gives Orizon interoperable command and control across multi-site manufacturing operations connecting factory machines, automation, and inspection equipment to existing enterprise systems for a unified operating environment. Real time data flows between machining, assembly, and quality systems enable autonomous process control and digital thread traceability for compliance in space, commercial, and defense programs.
“Next generation manufacturers like Orizon Aerostructures require real time orchestration across processing, assembly, and quality workflows,” said Tyler Bouchard, CEO & Co Founder of Flexxbotics. “We are proud to partner with Orizon to enable interoperable digitization for greater manufacturing autonomy with Flexxbotics.”
