HANNA AUGUSTA INDUSTRIAL | INDUSTRY INSIGHT

July 2025

Why Engines Don’t Fire: The Real Barriers to Progress in Aerospace and Manufacturing

Despite vast technical capability, aerospace programs and precision manufacturers still face delays, failures, and costly downtime. So why aren’t things working?

It’s not the machines. It’s the mindset.

Products don’t fail because of a lack of technology—they fail because we misuse specifications, let ego outpace evidence, and refuse to admit experience skill gaps. Now is the time to really take a second look at our manufacturing process, examine the real causes behind the misfires.

NASA’s Artemis I, launch delays of new propulsion technology—were caused by preventable fuel sensor failures and procedural gaps.

“Valve leaks and thermal issues reflected process failures more than hardware design.” — NASA OIG, 2023

Nasa, that’s great but kindly disagree because design has everything to do with the process.

Specifications

According to the Defense Acquisition University:

“Misinterpretation of specs is a top driver of quality failures.” — DAU Manufacturing Guide, 2021

At Hanna Augusta, we’ve audited shops where machinists were holding ±0.0005” tolerances with ±0.005” tooling—simply because the correct spec wasn’t communicated or updated.

Everyone Wants to Be the Boss

Competing engineers and contractors often withhold data or push conflicting agendas.

“Human spaceflight missions suffer from stovepipe thinking and territorial management.” — NASA Human Factors Report, 2022

Without aligned teams, even the best process fails. Process control dies in silos.

Faking It Until You Break It

According to NIST:

“Up to 20% of production loss stems from workforce skill mismatches.” — NIST Manufacturing Report, 2021

We see it constantly: teams pretending to understand new processes, skipping training, and avoiding questions. The result? Late deliveries. Scrap. Failed audits.

Not even going to lie, when people who can’t read a print correctly, claim to be experts; we get a little worried.

We Recommend

At Hanna Augusta Industrial, we don’t just diagnose—we rebuild. Our PFMEA + ROI methodology proves value through time studies and cost avoidance metrics.  We can physically see the savings/options.

Fix the process before you blame the people or the tools.

Here’s how:

Enforce spec-based processes with documented, visual checklists.

Break down departmental egos with cross-functional RCCA reviews.

Normalize skills testing and competency-based staffing.

Invest in improvement before your customer demands it.

RFQ world class process manufactures

Real-World Tip

“Sometimes, the engine doesn’t fire because someone didn’t know to replace the O-ring every time—and no one asked.” Let’s stop pretending we know every single O-ring and start fixing your crumpled face.

 References:

– NASA Inspector General (2023)

– NIST Manufacturing USA Report (2021)

– DAU Manufacturing Risk Assessment

– AS9100D Clause 7.5 – Documentation & Specs

– Hanna Augusta Industrial PFMEA ROI Method

 Interested in a process review or PFMEA investment forecast?

📨 Email: support@hannaindustrial.com

📞 1(564)226-2402

🌐 www.hannaindustrial.com