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Our Industrialization Process

Getting a design right is only part of the challenge. The transition from a validated prototype to a product that can be built repeatedly, to specification, at the volumes a programme requires, is where a lot of development effort either pays off or unravels. That transition is what our industrialization process is designed to manage.

We apply a structured industrialization methodology across our engineering and production sites in Toulouse, France and Hautcharage, Luxembourg, and our products are distributed globally, including through our commercial office in Austin, Texas. The same process framework applies regardless of product line, from space antennas to RF electronics and SDR platforms.

From First Design to Production-Ready: Our 10-Step Process

DFMEA/PFMEA

Before committing to a design direction, we run a Design Failure Mode and Effects Analysis to identify potential failure modes and their downstream consequences. In parallel, we develop the Process FMEA to anticipate assembly difficulties and define special processes early. Key characteristics are identified at this stage, which directly feeds the control plan.

Bill of Materials (BOM)

A comprehensive BOM is built from the preliminary design and immediately entered into our ERP system. This is the traceability backbone of the programme: every component has a reference, a source, and a qualification status from the moment it is defined.

Manufacturing Flow Chart

We map each manufacturing step in a detailed flow chart, identifying the sequence of operations, required equipment, and decision points. This exercise also surfaces potential bottlenecks early, when they are still manageable.

Control Plan & Process Control

A control plan is established to define how quality is monitored at each production step. We use MSA (Measurement System Analysis) to qualify our measurement equipment, and SPC (Statistical Process Control) to monitor process stability throughout the production run.

Prototype Production & Testing

Before moving to series production, a formal readiness review verifies that the design is frozen, the manufacturing process is stable, all documentation is complete, and the qualification results are satisfactory. Nothing moves forward without this gate being cleared.

Product Readiness Review (PRR)

PPAP Submission & Approval

In line with aerospace standards, a Production Part Approval Process package is prepared and submitted. PPAP demonstrates that the production process is capable of consistently producing product that meets all specified requirements.

First Article Inspection (FAI)

The first unit produced in series undergoes a comprehensive inspection against all design specifications and dimensional requirements. FAI is the formal confirmation that the production process delivers what the design intended.

Mass Production

Series production runs on the validated process, with all control plan checkpoints active. Traceability is maintained at unit level throughout, ensuring that any issue identified downstream can be traced back to its origin without ambiguity.

Continuous Monitoring & Improvement

Production data is collected and reviewed on an ongoing basis. Deviations from process norms trigger investigation. Improvements identified in production feed back into the DFMEA/PFMEA and control plan, closing the loop.

1. DFMEA/PFMEA
2. Bill of Materials (BOM)
3. Manufacturing Flow Chart
4. Control Plan & Process Control
5. Prototype Production & Testing
6. Product Readiness Review (PRR)
7. PPAP Submission & Approval
8. First Article Inspection (FAI)
9. Mass Production
10. Continuous Monitoring & Improvement

How We Think About Industrialization

Beyond the process steps, a few principles shape how we approach the industrialization work itself. They influence the decisions we make at each stage, particularly when there is a trade-off between performance, cost, and schedule.

FMEA as a Design Tool, Not a Compliance Exercise

We use FMEA from the very beginning of a programme, not as a document to be completed after the design is done. Running DFMEA and PFMEA early means that potential failure modes influence design decisions while there is still room to change things. By the time a product reaches prototype, the most significant risk scenarios have already been worked through on paper.

DfX: Design for What Actually Matters

DfX is a family of design approaches that includes Design for Manufacturing (DfM) and Design for Assembly (DfA), among others. The common thread is that downstream constraints are taken into account upstream, during the design phase, rather than discovered when it is too late to address them without rework. For us this means that our mechanical engineers, electronics specialists, and production teams are involved in design reviews from early in the programme, not brought in at the end.

Lean Manufacturing: Eliminating What Does Not Add Value

We apply lean manufacturing principles throughout our production process, with a focus on reducing waste in the form of excess inventory, unnecessary handling, and process steps that do not contribute to product quality. The goal is not to cut corners but to identify and remove the activities that consume time and cost without adding anything the customer values.

What it means for your Programme

Fewer Surprises at Qualification

The DFMEA, PFMEA, and prototype testing phases are designed to surface problems early, when the cost of addressing them is still manageable. A programme that finds a significant issue at qualification is in a fundamentally different situation from one that found and resolved the same issue at prototype stage. Our process is structured to push discovery as far upstream as possible.

Repeatable Results Across Units

The combination of a frozen design, a validated production process, and a live control plan means that unit-to-unit variation is understood and controlled. When you order a second batch of a product six months after the first, you can expect the same performance. That predictability matters for programmes where spares and replacements need to be interchangeable.

Full Traceability from BOM to Delivery

Every component reference, every production step, and every inspection result is linked to the specific unit it applies to, from the moment the BOM is entered in the ERP through to final acceptance. If a question arises at any point in the programme, the answer is in the records.

A Process that Scales

Our industrialization framework was designed with scalability in mind. Moving from prototype quantities to series production does not require rebuilding the process from scratch. The PPAP and FAI steps exist precisely to validate that the transition has been made correctly, and the production monitoring in place from step one means that scaling up does not introduce quality risk.

Planning a new programme?

Whether you are at the stage of preliminary design and want to understand how our industrialization process fits your programme timeline, or you are looking for a production partner for an existing product, we are happy to discuss what your programme actually needs.

Questions & Answers

  • When should industrialization start in a space programme?

    Industrialization should begin during the design phase, not after. Early integration of DFMEA, PFMEA and DfX principles ensures that manufacturability, reliability and scalability are built into the product from the start.

  • What is the main risk when moving from prototype to production?

    The main risk is that the prototype does not accurately represent the series product. Differences in materials, processes or assembly methods can invalidate test results. Our approach is to build prototypes using the same processes intended for production.

  • How do you ensure production consistency?

    Through a combination of a frozen design baseline, validated manufacturing processes, SPC monitoring, and strict traceability at unit level. This ensures controlled variation and repeatable performance across batches.

  • What role does PPAP play in your process?

    PPAP formally demonstrates that the production process is capable of consistently meeting all technical requirements. It is a key validation step before full-scale production is authorised

  • Can your process scale to higher production volumes?

    Yes. The industrialization framework is designed to scale without changing the core process. Validation steps such as PRR, PPAP and FAI ensure that scaling does not introduce additional risk.

Space hardware industrialization for reliable and scalable production

Industrializing space hardware requires more than validating a design. It involves building a controlled, repeatable and traceable production process capable of delivering consistent performance across multiple units and production cycles.

At Anywaves, our industrialization methodology integrates DFMEA, PFMEA, control plans, and aerospace-standard validation steps such as PPAP and First Article Inspection. This structured approach ensures that risks are identified early, manufacturing processes are stabilised before production, and product performance remains consistent from prototype to series.

Our teams support satellite manufacturers and payload integrators in transitioning from design to production, ensuring scalability, traceability and compliance with space industry standards.

From RF antennas to active electronics and SDR platforms, we deliver industrialized space hardware ready for reliable deployment in orbit.

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