How Flying S is Turning Data into a Competitive Advantage

Case Study from | Datanomix Production Monitoring

11/24/25, 08:29 PM | Automation & IIoT, Engineering | Datanomix

Aerospace Is Changing Fast — and Production Data Is the New Competitive Edge

The aerospace supply chain has never moved faster. Customers expect flawless parts, faster turnarounds, and proof that real production data backs every component.

For manufacturers like Flying S in Palestine, IL, meeting those expectations means embracing digital transformation through modern manufacturing technologies that go beyond gut feel and manual tracking.

As automation, multi-axis machining, and lights-out operations become the norm, shops are realizing that the real advantage doesn’t come from just running more machines; it comes from understanding how they’re running. That’s where production monitoring software makes the difference, giving manufacturers the real-time visibility to make data-driven decisions with confidence.

The Challenge: Scaling Complexity Without Losing Sight of Performance

Flying S has earned a reputation in aerospace for precision, quality, and innovation. With complex parts, lengthy cycle times, and a growing fleet of automated machining centers, the company faced a new challenge: how to maintain control as the shop becomes more advanced?

Operators were juggling multiple machines, programmers needed real-time feedback, and leadership wanted to understand what was really driving downtime and throughput. Relying on spreadsheets, shop-floor chatter, or best guesses wasn’t enough.

“We wanted to know why our machines were stopped. Is it operators, inspection, tooling, or something else? Instead of taking people’s word for it, we wanted to see the data.”

— Kyle Myers, Engineer at Flying S

Flying S needed a solution that could automatically capture and interpret what was happening across every cell and every shift—without adding extra work to the team.

The Solution: Datanomix Real-Time Production Monitoring

Flying S turned to Datanomix to bring the machine to the forefront of operations and improvements. With a simple Ethernet connection to each machine, Datanomix automatically collects production data with no operator input required and transforms it into live insights on uptime, downtime, cycle times, and performance trends.

What began as a simple question—“Is my machine still running?”—quickly evolved into a strategic plan for continuous improvement across the shop floor.

“One of the first things we really love to see is the actual cycle time. How long does it take to get the first part and make the rest? How can we make that better?”

— Kyle Myers, Engineer at Flying S

Suddenly, everyone from machinists to managers had access to the same real-time truth. The shop could see actual cycle times versus CAM estimates, understand when and why machines stopped, and uncover new opportunities for optimization.

Behind the Screens: How Data Changed the Conversation

Once Flying S started reviewing production data from Datanomix, everything changed. During one leadership meeting, Engineering Manager Kyle Myers brought in detailed reports showing yesterday’s machine utilization, downtime, and cycle efficiency. As the team reviewed the charts, long-held assumptions were challenged and next-step decisions became grounded in fact.

“Several people’s assumptions were changed. They could actually see it now. That’s exactly why I like data.”

— Kyle Myers, Engineer at Flying S

Even the machinists got competitive. They began tracking their own numbers, seeing how fast they could safely and accurately complete a run, transforming machine monitoring into a motivator for continuous improvement.

For engineering and operations, the insights were game-changing. Actual cycle times and true production data replaced estimates, improving quoting accuracy, scheduling, and customer communication.

Results: Turning Data into Measurable Gains

The impact of Datanomix was immediate and measurable. With real-time production monitoring driving continuous improvement, Flying S transformed visibility into real operational performance gains. The company achieved a 9% increase in uptime, an 8% increase in utilization, and an impressive 18% decrease in downtime, a standout metric that highlights how effectively the team is using their machines.

These improvements translate into 136 additional productive hours per machine per year, delivering roughly $10,909 in additional productivity per machine and a 5X return on investment for their Datanomix implementation.

“Datanomix is honestly the easiest software company I’ve ever had to work with. Integration was simple, and the data started flowing right away.”

— Kyle Myers, Engineering Manager, Flying S

Flying S has built a smarter, faster, and more predictable operation, proving that data truly is a competitive advantage in modern manufacturing. Watch the Full Flying S Story to see how they’re transforming production data into actionable insights.

About Datanomix

Datanomix delivers real-time production monitoring and machine monitoring software that helps precision manufacturers turn data into action without adding extra work to the shop floor. By automatically connecting to CNC machines and analyzing performance, Datanomix provides the insights manufacturers need to improve productivity, quoting accuracy, and confidence in every decision.

Learn more at www.datanomix.io.

The content & opinions in this article are the author’s and do not necessarily represent the views of ManufacturingTomorrow

Datanomix

Datanomix empowers manufacturers of all sizes to increase productivity and profitability through its Data-Powered Production™ solutions. Its product portfolio includes Production Monitoring, G-Code Cloud™ + DNC, TMAC AI™, and ToolAnalytix™ - all designed to turn machine data into actionable insights with zero operator input. Headquartered in New Hampshire, Datanomix software analyzes real-time production signals to identify bottlenecks, improve quality, and provide prescriptive coaching to drive continuous improvement. For more information, visit www.datanomix.io.

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11/24/25, 08:29 PM | Automation & IIoT, Engineering | Datanomix

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