How strategic choices are poweringaerospace’s next decade Contents Foreword 01 Execu�ve summary 02 Accelera�ng toward a human-centric, AI-guided future 03 Digital twins on the rise across the aerospace ecosystem 06 A faster, ver�cal future takes flight with AAM 08 MRO providers push to digi�ze and scale 10 Pivot-ready supply chains remain elusive 12 Next steps: Strategic focus areas for future-ready skies 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 longersimply reac�ng to disrup�on; it is laying thefounda�on forFuture-Ready Skies that are safe,secure, predictable, reliable, and sustainable. 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 asdark factory opera�ons, powered by intelligentrobo�cs, analy�cs, and AI.70% of advanced air mobility companies are already pursuing commercial 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 sourcingwithin 30 daysof a Tier-1 disrup�on, illustra�ng the need for supply chains that areintelligent,resilient, and perpetually adap�ve. 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 markrearchitecturing of the industry, where decision intelligence, AI-driven opera�ons, and humanexper�se are deeply intertwined. 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 leadthe next decade of flight. 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 challengingestablished norms. Simultaneously, supply chains are being reconfigured for resilience, andmaintenance opera�ons are transi�oning from cost centers to strategic value drivers. 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. Ourresearch iden�fies three key findings from our survey respondents: 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,and enhancing passenger experience. Data con�nues to be a differen�atorfor our customers with many rethinking their enterprise-wide data strategiesto fully leverage the benefits of AI. – Ozgur Tohumcu, General Manager - Automotive & Manufacturing,Amazon Web Services (AWS) 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). Themajority an�cipate a hybrid approach, with con�nued human oversight for an ave