A Review of the Process Control System in Aero-Composite Manufacturing Operations

This research examines the application of environmental control within the Process Control System (PCS) in the aerospace industry, specifically focusing on AS9100 quality assurance. The single case study was conducted at a Malaysian aerospace composite manufacturer, pseudonymously identified as XYZ, due to its significance in the worldwide aerospace supply chain, AS9100 certification, and its position as a leading aerospace composite manufacturer. Using qualitative methods, this study explored the management of temperature, humidity, and contamination in Controlled Contamination Areas (CCA) and Environmentally Monitored Areas (EMA), drawing on observations, PCS document reviews, and semi-structured interviews with key operational personnel. The results of the case study suggest that Company XYZ's PCS achieves compliance and uniformity in operations, but its current conventional approach does not adequately support defect mitigation and process improvement. The study suggests the implementation of an integrated PCS, advocating the use of IoT devices, predictive analytics, and digital twins for real-time control for process reliability. This leads to a decrease in wastage, enhanced product quality, and facilitates the cycle of continual improvement. The study also discusses the roles of quality management system employees, organisational culture, and integrated maintenance as pillars of system sustainment. This research demonstrates the application of integrated environmental control within the PCS and its linkage to operational excellence and global competitiveness to advance the aerospace industry.