How strategic choices are poweringaerospace’s next decade Contents Foreword01 Execu�ve summary 03 Digital twins on the rise across the aerospace ecosystem A faster, ver�cal future takes flight with AAM MRO providers push to digi�ze and scale 10 12 Pivot-ready supply chains remain elusive 13 Foreword Charting theFuture-Ready Skies Aerospace has always been an industry whereambi�on is matched by precision and safety. Today,that ambi�on is being redefined as technology movesfrom suppor�ng opera�ons to shaping enterprisestrategy—transforming how aircra� are designed,manufactured, and operated. The industry is no longer Anupam SinghalPresident - ManufacturingTata Consultancy Services This study captures the sector at a pivotal moment.Manufacturers an�cipate that within the next five toseven years,40% of aerospace produc�on will run as robo�cs, analy�cs, and AI.70% of advanced air mobility companies are already pursuingcommercial ini�a�ves, accelera�ng the transforma�on of infrastructure, scale, and business models.Yet this momentum coexists with fragility—only28% of execu�ves say they could pivot sourcing The shi� extends well beyond manufacturing. In maintenance, repair, and overhaul,64% of providersexpect measurable ROI from predic�ve analy�cs and AI-driven maintenance within five years,demonstra�ng how intelligence is redefining performance economics. Together, these trends mark At TCS, we see this moment as aleadership opportunity. Aerospace enterprises that designintelligence into their opera�ons, embrace adaptability, and empower their people with AI will lead I believe this report provides a meaningful perspec�ve for leaders ready to act boldly. It reaffirms ourbelief that the skies we are building are not only connected and sustainable, but future-defining. Executive summary This report, based on a survey of 323 senior aerospace industry leaders across North America andEurope, reveals an industry in transi�on. Tradi�onal manufacturing norms are being reimagined,while new entrants in the electric ver�cal takeoff and landing (eVTOL) segment are challenging Spanning three core segments – aerospace manufacturers, advanced air mobility (AAM) companies,and MRO providers – the findings offer a snapshot of how aerospace manufacturers and operatorsare priori�zing investments, naviga�ng barriers, and recalibra�ng for supply chain resilience. Our On average, respondents an�cipate 40% of their manufacturing opera�ons to be lights-out,requiring minimal human interven�on, within the next 5-7 years Nearly three-fourths (70%) of AAM companies are ac�vely building or involved in commercialprojects Less than a third (28%) of respondents across all segments say they can reroute sourcing within30 days of a Tier 1 shock In our work with our customers, we see that AI is transforming the valuechains across the aerospace industry leading to improved product design anddevelopment, predic�ve maintenance, enhanced safety and riskmanagement, opera�ons op�miza�on, and improved autonomous flightcapabili�es. We are seeing increased interest in AI applica�ons driving realbusiness value focusing on reducing opera�onal costs, improving efficiency, Accelerating toward a human-centric,AI-guided future Digital transforma�on and advanced technologies are unlocking new fron�ers in predic�ve analy�cs,automa�on, and immersive tools. But how far will autonomy go for the aerospace industry? Despite interest in automa�on, expecta�ons for “lights-out” factories – a fully automatedmanufacturing process where produc�on opera�ons occur with minimal to no human interac�on orpresence – remain tempered. While ambi�on is high, aerospace manufacturers surveyed expect lessthan half (40%) on average of their opera�ons to be fully lights-out by 2032 (see Figure 1). The On average, companies foresee of their manufacturing opera�ons requiringhuman involvement in 5-7 years Figure 1.Aerospace manufacturers:What percentage of your manufacturing operations will likely requirehuman intervention in 5-7 years and what percentage will be running autonomously? (n=135) The MRO providers we surveyed largely concur with manufacturers on autonomy. When asked aboutthe expected level of autonomy in MRO by the end of the decade, few MRO providers surveyedexpect fully autonomous MRO workflows for rou�ne tasks, yet around a third envision Figure 2.MRO providers:What level of autonomy do you expect your Maintenance, Repair and Overhaul(MRO) operations to achieve by 2030? (n=138) The remainder expect human-led maintenance to persist. While MRO providers have been heavilyinves�ng in digital technologies (such as mobile task cards for technicians, digital planning, andconnected data insights), further advances in autonomy would require significant digitaliza�on and In addi�on, the rise of agen�c AI is adding anew dimension to the push toward autonomousopera�ons. This shi� is reshaping how decisionsare made by harnessing AI and applying it tohighl