Faceplates and Overlays
In aerospace manufacturing, precision is everything. Every part must meet strict customer requirements, and even one missing specification can lead to failed testing, production delays, and additional costs.
At PPS, we understand that producing a quality part is only part of the job. We also help customers identify potential issues before they become costly problems.
A recent project demonstrated just how valuable that approach can be.
The Challenge
A customer needed parts manufactured according to an approved engineering drawing. The parts were produced using a proven manufacturing process that had been successfully used for many years. They met every requirement listed on the drawing and passed the required electrical continuity specifications.
However, during qualification testing, the customer discovered the parts did not meet an additional insulation resistance requirement.
At first, this was confusing because the parts had been manufactured exactly as specified. After reviewing the project with the customer, PPS discovered that the insulation resistance requirement was not included in the original drawing package used during production.
Instead, it had been added through a separate customer document that was not initially provided.
Without access to that additional requirement, the parts were manufactured correctly—but they were not built to the customer’s complete expectations.
Finding the Root Cause
Rather than simply replacing the parts, the PPS team worked closely with the customer to understand why the issue occurred.
Together, we reviewed the engineering drawing, qualification testing procedures, and all available project documentation.
That investigation quickly revealed the problem. The manufacturing process itself was not the issue. Instead, an important customer requirement had not been communicated during the early stages of production.
Once the missing specification was identified, everyone involved had a clear path forward.
The PPS Solution
Our team immediately worked with the customer to ensure future production would meet every requirement.
PPS helped by:
- Reviewing all customer documentation.
- Identifying the missing insulation resistance requirement.
- Confirming the manufacturing process could meet the updated specification.
- Updating production documentation to include the complete requirements.
- Aligning the manufacturing process with the customer’s qualification standards.
Because the supplier was already capable of producing parts that met the new specification, only the documentation and manufacturing instructions needed to be updated.
The result was a permanent solution that helps prevent the same issue from happening again.
Why Documentation Matters
Many people assume the engineering drawing contains every manufacturing requirement.
In reality, that’s not always the case.
Especially in aerospace and defense manufacturing, additional customer specifications, qualification requirements, and revision updates may exist outside of the drawing itself.
If those documents aren’t reviewed together, manufacturers can unknowingly miss an important requirement—even while producing a high-quality part.
That’s why careful documentation review is just as important as precision manufacturing.
Taking the time to verify every requirement before production begins can help reduce rework, improve compliance, and keep projects on schedule.
More Than a Print Supplier
At PPS, we believe our role goes beyond manufacturing products.
Whether we’re producing aerospace labels, industrial labels, graphic overlays, membrane switches, nameplates, or other custom printed components, our team works closely with customers to understand their application and verify project requirements before production begins.
We know that our customers rely on us for more than quality printing. They rely on us to help identify potential issues early, communicate clearly throughout the project, and deliver products that meet demanding industry standards.
This collaborative approach helps reduce risk, improve efficiency, and build long-term partnerships with manufacturers across the aerospace, defense, medical, industrial, and technology industries.
Partner with PPS
Complex manufacturing projects require more than a supplier—they require a partner who pays attention to the details.
At PPS, we’re committed to helping customers solve problems, improve manufacturing processes, and deliver products that meet quality and compliance requirements from the very beginning.
If you’re looking for a trusted partner for aerospace labels, durable industrial labels, graphic overlays, membrane switches, industrial nameplates, or other custom printed components, we’d love to help.
Contact PPS today to discuss your next project and discover how our experienced team can help keep your production moving forward with confidence.