Case Study: Leonardo achieves reduced Defect Per Unit and faster production throughput with IntraStage

Leonardo - Customer Case Study

Leonardo, an advanced engineering company in the aerospace and defense sector (formerly Selex Electronics Systems/Selex Galileo), faced the need to identify and minimize manufacturing and repair touch time, investigate yield and performance issues across multiple secure sites, and normalize disparate test data from ATML, NI TestStand, LabVIEW TDMS, PDF and various text/CSV/Excel formats. To tackle these challenges they engaged IntraStage to centralize and standardize their test and production data.

IntraStage implemented continuous aggregation of manufacturing and field/return data (Integration, ESS Thermal, ESS Vibration, Pre‑ATP, ATP) and normalized hundreds of metadata points across many file formats, enabling identification of trends such as station-to-station measurement variation, test‑software effects, and operator impact. As a result, IntraStage helped Leonardo improve their DPU rate within two months, reduce Defect Per Unit for high‑value assemblies, speed production throughput, minimize touch time, provide a single source of truth for as‑built performance, and enable multi‑site collaboration while reducing demand on high‑value resources.

Leonardo