Client Overview

Cirrus Aircraft is a leading American aircraft manufacturer, recognized for innovation and safety features like the Cirrus Airframe Parachute System (CAPS). With a reputation for premium personal aircraft, Cirrus needed to modernize its digital ecosystem to improve efficiency, maintain FAA compliance, and enhance customer experience.

The Challenge

Cirrus faced four critical business challenges:

Disconnected systems across the enterprise. Windchill PLM, Solumina MES, Avante ERP, and Salesforce CPQ operated as silos. Engineering couldn't see manufacturing status. Manufacturing couldn't track design changes. Sales quoted configurations that engineering hadn't validated.

Complex lifecycle management. Aircraft stay in service for decades. Each plane has a unique configuration with options, modifications, and service history. Managing this complexity across disconnected systems created errors and delays.

Manual FAA certification processes. Compliance documentation required manual reconciliation between engineering designs, manufacturing records, and certification requirements. This process was slow, error-prone, and created audit risk.

No connected experience for aircraft owners. Customers needed visibility into their aircraft's service history, warranty status, and maintenance requirements. Data existed in multiple systems but wasn't accessible in one place.

The Element Approach

Element Consulting implemented an end-to-end digital thread connecting Cirrus's four core systems:

Phase 1: Digital Thread Architecture

• Mapped data flow from CPQ quote → Engineering design → Manufacturing build → Service records

• Connected Salesforce CPQ, Windchill PLM, Solumina MES, and Avante ERP

• Created digital thread diagrams showing how data moves between systems

• Defined interface specifications for each connection point

Phase 2: Process Optimization

• Implemented Manufacturing Process Management (MPM) in Windchill

• Created decision matrix for when to use Solumina vs. Windchill for work instructions

• Defined engineering BOM structure to support product options and variants

• Established governance model for maintaining digital thread

Phase 3: Regulatory Compliance Integration

• Streamlined FAA certification workflow using Solumina MES

• Automated reconciliation between engineering records and manufacturing as-built data

• Created digital trace from design through production for certification documentation

• Reduced manual reconciliation time by 88%

Phase 4: Customer Portal Enhancement

• Connected aircraft configuration data to customer-facing portal

• Enabled real-time visibility into service history and warranty status

• Automated maintenance scheduling based on aircraft usage data

• Created foundation for future AI-powered predictive maintenance

The Results

Operational efficiency improved through elimination of manual data transfer. Engineering changes now flow automatically to manufacturing. Manufacturing status is visible in real-time to engineering and sales.

FAA compliance accelerated significantly. What previously required days of manual reconciliation now happens automatically. Audit trail is complete and digital.

Customer engagement enhanced through connected digital experience. Aircraft owners can see complete service history, schedule maintenance, and track warranty coverage in one portal.

Scalable foundation established for future innovation. Digital thread architecture supports adding AI analytics, IoT sensor integration, and predictive maintenance capabilities.

Key Outcomes:

• 88% reduction in FAA certification reconciliation time

• Automated data flow between four enterprise systems

• Complete digital thread from quote through service

• Customer portal with real-time aircraft data

• Foundation for AI and IoT integration

What Cirrus Says

"Element didn't just connect our systems. They built a digital thread that follows each aircraft through its entire lifecycle. From the first sales quote through decades of service, we now have one connected view."

— VP Operations, Cirrus Aircraft

Lessons Learned

Integration across systems is critical for data integrity. Point-to-point connections aren't enough. The digital thread must maintain data relationships as information moves between systems.

Change management and training are essential for success. Technology enablement alone doesn't drive adoption. Cirrus invested in change champions, training programs, and ongoing support.

Digital tools drive customer loyalty and transparency. The customer portal has become a competitive differentiator. Aircraft owners appreciate the transparency and convenience.

Project Details:

• Industry: Aerospace Manufacturing

• Systems Integrated: Windchill PLM, Salesforce CPQ, Solumina MES, Avante ERP

• Project Duration: 18 months (phased implementation)

• Users Affected: 300+ across engineering, manufacturing, quality, and service