Machines that can’t be patched can still be protected.

An aircraft-skin cutter running an operating system nobody can patch. A tier-two supplier sitting on a design-change backlog while a launch date gets closer. GrayMatter’s Insiders work both sides, on your floor and on your suppliers’, protecting what’s running and fixing what’s slowing the program without taking the line down.

Solutions from your floor to the supplier’s dock.

Your equipment is meant to run for decades, and your supply chain has to hit dates set years in advance. GrayMatter solves the operational problems that put program timelines, safety equipment, and legacy capital investment at risk.

Legacy operating systems on custom-built manufacturing equipment can’t always be patched. When they’re infected, they get reinfected almost immediately after cleanup, with no way to isolate the problem. GrayMatter deploys network micro-segmentation that contains infected machines without disrupting the rest of the plant, tested gradually on one network segment before scaling further.

A fragmented supplier network with no shared visibility into backlog, quality, or inventory can quietly become the biggest risk to a program launch. GrayMatter assesses supplier capacity and capability, builds governance around design-change backlogs, and puts quality control on-site at the suppliers that matter most, turning a disconnected network into one with a shared, current picture of the program.

Structured problem-solving and shared learning loops that work at a single facility don’t automatically spread to the rest of a manufacturing network — and low-volume, high-complexity production (the kind aerospace and defense programs run on) makes that harder. GrayMatter builds the standardized decision-making and synchronized readiness practices that let a win at one site become the way every site operates.

From rotorcraft lines to seat shells.

GrayMatter works across the aerospace and defense manufacturing landscape — from legacy aircraft production floors to the supplier networks and next-generation space programs behind them. We carry the cybersecurity and program experience to fix the problems that hold every subsector back.

Commercial & military aircraft manufacturing

Legacy equipment protection and OT cybersecurity for rotorcraft and fixed-wing manufacturers running dual civilian and military production lines.

Aerostructures & airframe components

Network segmentation for legacy machining and fabrication equipment that can’t easily be patched or economically replaced.

Aircraft interiors & supplier networks

Supplier evaluation, backlog governance, and on-site quality control for high-stakes commercial aircraft interior and component programs.

Commercial space & new space manufacturing

Scaling low-volume, high-complexity space hardware production toward repeatable, industrialized manufacturing.

Why GrayMatter

Prove success on one machine, then scale it.

Aerospace and defense manufacturers can’t afford to gamble a production line on an unproven fix. GrayMatter tests before it scales — proving an approach on one machine or one network segment first, containing the risk, before extending it further. That’s what lets us protect the legacy equipment already on your floor and keep programs on schedule, without the cost or downtime of a forklift upgrade.

Industry Insight

Paul Heasman, Managing Director, Factory Advisors

The new space race: Why winning the moon will require more than rocket science

GrayMatter’s take on the commercial space sector: winning the new space race won’t come down to rocket technology alone, but to which organizations can turn extraordinary ideas into repeatable processes and scalable, industrialized production — citing NASA’s Artemis program, China’s lunar ambitions, and SpaceX’s Falcon 9 as examples of what industrialized space production looks like in practice.

“The organizations that lead the next era of exploration may not simply be those that design the most advanced technologies. They may be those that learn how to industrialize those technologies faster than their competitors.”

No machine too old, no network too slow

Our aerospace and defense Insiders have secured legacy production equipment and rebuilt supplier networks behind aircraft program launches.

Talk with a Factory Advisor

FAQs

Yes. Network micro-segmentation isolates legacy machines so malware can’t spread between them or come back after cleanup, without replacing the equipment. It’s tested gradually, one network segment at a time, before scaling further.

Yes. Our work spans commercial and military aircraft manufacturing, including facilities running dual-use production across multiple sites.

Yes. We assess supplier capacity, capability, and quality control, build governance around design-change backlogs, and place quality staff on-site at the suppliers that matter most. For one aerospace safety-equipment maker, supplier on-time delivery went from 94% to more than 98% within a month.

Yes. Low-rate, high-complexity production needs a different approach than high-volume lean. It calls for standardized decision-making and shared learning loops rather than the physical-flow efficiency tactics built for high-volume lines.

Yes. We build supply-chain reporting for visibility, analyze the root causes of shortages, and adjust buffer stock levels so inventory problems get caught before they cause a missed delivery.

Yes. GrayMatter supports clients seeking to comply with cybersecurity frameworks, including NIST SP 800-171 and CMMC.