Closed Loop Product Lifecycle Sama & Digital Twin Alignment
An aerospace and defense contractor manufacturing satellite systems, avionics enclosures, and unmanned aerial vehicles.
Run on Sama · Traceability & Product Data
The challenge
BOM data was fragmented across disconnected PLM, ERP, MES, and MRO software systems throughout the 20 year product lifecycle.
As designed, as planned, as built, and as maintained BOM baselines diverged over time, making traceability audits slow and risky.
Defense audit compliance required 100% serialized component traceability, which took weeks of manual records retrieval for each aircraft.
How Sama solves it
Lifecycle Digital Thread Backbone
Sama connects As Designed (EBOM), As Planned (MBOM), As Built (MES), and As Maintained (SBOM) into one synchronized digital thread.
Automated Serialized Component Traceability
Records exact component lot numbers, serial numbers, and calibration certificates for every manufactured unit.
Real Time Lifecycle Baseline Comparison
Highlights deltas between the original design specification and current field operating configurations.
Closed Loop Field Failure Engineering Feedback
Feeds field maintenance failure data directly back into R&D; engineering BOMs to inform future design revisions.
One Click Defense Audit Dossier Export
Generates certified, audit ready digital twin dossiers compliant with AS9100 and defense procurement mandates.
The outcome
- traceability audit preparation time cut
- 0 weekstraceability audit preparation time cut
- data integrity maintained across 20 year product lifecycle
- 0%data integrity maintained across 20 year product lifecycle
Traceability audit preparation time cut from 3 weeks to under 60 seconds.
100% data integrity maintained across 20 year product lifecycle digital threads.
Accelerated engineering design improvement cycles by 35% through closed loop field reliability feedback.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
More from Sama
Engineering
Harmonizing EBOM to MBOM Discrepancies During Electric Vehicle Ramp
An Electric Vehicle (EV) original equipment manufacturer ramping up a new dual motor SUV platform across two high volume vehicle assembly plants.
Engineering
Aligning Hardware EBOM and Embedded Firmware Software BOM
A smart automotive Tier 1 supplier producing Advanced Driver Assistance System (ADAS) domain controllers integrating radar sensors, cameras, and microcontrollers.
Finance
Field Service BOM Alignment for Warranty & Aftermarket Operations
A commercial bus and truck manufacturer with a global dealer network managing 150,000 active fleet vehicles across 25 international markets.
Bring us the version of this that you actually have.
Every engagement is fixed-scope and outcome-guaranteed. The scoping conversation starts with your systems, not with a template.