Why Legacy Systems Are Holding Back Aerospace Manufacturers

Aerospace manufacturing runs on precision, regulation, and strict timelines. However, many companies still depend on outdated ERP (Enterprise Resource Planning) systems to manage everything. These older tools weren’t designed for today’s rapid environment, where requirements frequently change and digital tools are expected to perform together. Holding on to legacy ERP means higher long-term costs, more manual work, and a greater risk of falling behind. Below, we’ll look at what that means in practice, and why switching to cloud-based aerospace ERP software is the new standard.

The Hidden Costs of Sticking with Legacy ERP

Legacy ERP systems may seem cheaper at first, but the long-term costs quickly add up. You’re not simply paying for hardware, licenses, and upgrades. You’re also covering maintenance and security patches. In fact, the total cost of ownership of running a single legacy system can be more burdensome than you think.

Then there’s the cost of time. IT teams typically spend most of their energy keeping outdated systems running instead of working on new ideas. Plus, older systems make it more challenging to grow, connect with modern tools, and meet shifting business needs. Mndwrk found that up to 80% of IT budgets go to maintenance alone, leaving little room for improvement needs.

Staying Compliant Is Getting Harder

The ERP aerospace industry faces strict and ever-changing requirements. Legacy systems weren’t designed to keep up, and that creates challenges. From meeting standards like ITAR (International Traffic in Arms Regulation) and NIST (National Institute of Standards and Technology) to protecting company data, older tools frequently fall short. Let’s break it down.

Aerospace-Specific Requirements Are Changing

Regulations like AS9100 (Aerospace Standard 9100), NIST, CMMC (Cybersecurity Maturity Model Certification), and ITAR change constantly. At the same time, customers and partners expect more from their suppliers, especially as it concerns traceability, quality checks, and product tracking. Legacy systems generally can’t handle things such as bill of materials traceability or audit trails. Today’s ERP for aerospace needs to be flexible enough to adjust quickly. It doesn’t matter if it’s a new reporting system or an update to a compliance standard.

Legacy Systems Can’t Keep Up with Cybersecurity Standards

Cyberattacks are increasing, and older ERP systems are easy targets. On-premise setups are especially vulnerable to ransomware, phishing, and data breaches. Between January 2024 and April 2025, the aviation industry saw a 600% jump in ransomware attacks, with 27 major incidents tied to 22 different groups. And 71% of those attacks involved stolen credentials or unauthorized access.

Modern ERP platforms, especially in the cloud, offer more secure protection. As one expert said, “We’ve never had a company have a ransomware issue in the cloud.” Legacy tools also don’t have features like multi-factor authentication or encrypted backups, things that are now expected.

Related Article: Simplify Your CMMC Compliance Journey with WM Synergy and NeoSystems

For aerospace manufacturers working with the Defense Industrial Base, meeting CMMC standards is essential. This guide shows how WM Synergy and NeoSystems provide a clear, step-by-step approach—from assessment to ongoing monitoring—so you can strengthen cybersecurity, stay compliant, and remain competitive in defense contracts.

Outdated Tools Slow Everything Down

When ERP systems can’t keep up with how work gets done, it impacts teams across the board. Many aerospace manufacturers end up using spreadsheets, emails, and other workarounds to avoid falling behind. Over time, this slows proficiency and creates more room for blunders.

In fact, 48% of workers waste three hours or more per day due to inefficient legacy systems, which costs the average business at least £28,000 annually in lost productivity.

Manual Workloads and Data Silos

Older ERPs also typically don’t connect with other systems. This means teams have to enter the same information in multiple places, which creates extra steps in finance, production, and engineering. The more hands involved, the higher the chance something gets missed. Instead of making updates once, teams juggle disconnected tools, leading to holdups and frustration. Many manufacturers even build custom patches or outside tools so that legacy systems can meet today’s needs.

Lack of Real-Time Visibility Across the Supply Chain

Legacy ERPs weren’t designed to show what’s happening at the moment. Teams often depend on outdated reports or email updates to track supplier performance, shipments, or production timelines. That makes it harder to adjust quickly when something changes. Cloud-based ERP for aerospace gives users dashboards, alerts, and real-time data across the supply chain, so everyone can make informed decisions faster.

The Risk of Falling Behind

Aerospace companies that move to modern ERP are already seeing the benefits. Better tools mean faster decisions and fewer disruptions. Sticking with legacy systems makes it more challenging to keep up, and that could mean losing contracts or customers.

These disruptions cost aerospace manufacturers an average of $184 million per year, with Aircraft on Ground (AOG) events costing the global airline industry an estimated $50 billion annually. Boeing estimates AOG costs airlines $10,000 to $20,000 per hour, or even as much as $100,000 in lost revenue, depending on the situation.

What Modern Cloud ERP Brings to the Table

New ERP platforms are designed to meet today’s aerospace needs. They’re easier to maintain and better at meeting security standards. Most importantly, they’ll be ready for whatever the future holds. Here’s how they’re different.

Related Article: How to Select Cloud ERP Software That Makes Sense for Your Company

For aerospace manufacturers, replacing outdated systems with the right cloud ERP is key to staying competitive. This guide explains how to match ERP features to your needs, improve efficiency, strengthen compliance, and prepare for growth—so you can leave legacy limitations behind.

Stronger Security and Built-in Compliance

Cloud ERP systems come with multiple layers of protection, such as firewalls and encryption. Updates happen automatically, so companies aren’t stuck with outdated software. Most modern platforms also include built-in audit trails and activity tracking.

For the aerospace industry, these systems are built to meet strict standards like CMMC, ITAR, and FedRAMP (Federal Risk and Authorization Management Program). WM Synergy’s FedRAMP-certified cloud ERP is one of the few options trusted by aerospace, defense, and government contractors. This makes it a good fit for regulated work.

Ready to Grow with Your Business

A good cloud ERP doesn’t hold you back when your company grows or changes. It scales up for new locations, product lines, or mergers. It also connects more easily with other software, such as PLM (Product Lifecycle Management) systems or supplier portals. This way, your teams don’t get stuck switching between platforms.

Because it’s created for flexibility, cloud ERP also works better for today’s workforce. Remote teams can log in from anywhere, and mobile tools keep people connected on the floor.

AI and Automation Readiness

Cloud platforms are designed to function with modern tech like artificial intelligence, robotic process automation (RPA), and machine learning. These tools won’t work on older systems. With cloud ERP, aerospace companies can unlock predictive insights and prepare for future advancements that rely on integrated, up-to-date data.

How WM Synergy Aids Aerospace ERP Project

Making the switch to modern ERP takes a team that understands your industry. WM Synergy brings hands-on experience, compliance knowledge, and a partner mindset to every project.

What is the purpose of conducting a pilot run during the ERP implementation process?

A pilot run tests the ERP system in a controlled setting before full launch. It helps find and fix problems, confirm the system works with real data, and ensure users are comfortable with the new processes. This reduces the risk of costly issues after go-live.

FedRAMP Certification and Industry-Specific Support

WM Synergy offers one of the few FedRAMP-certified ERP systems available. That makes it a trusted choice for aerospace manufacturers and government suppliers who need to adhere to strict cybersecurity and compliance requirements.

Beyond the software itself, WM Synergy remains involved as standards change. Their team provides ongoing assistance for audits and compliance updates. This way, companies don’t have to navigate it alone.

Hands-On Consulting for Actual Change

WM Synergy works alongside teams to make changes happen. Their Center of Excellence team works onsite to guide lean practices, 5S improvements, and cultural shifts.

As CEO Paul Tedford said, “Our people actually got in the vats and helped them clean it. That’s because we’re in this with you as partners.” From language inclusivity to team-building, they focus on long-term success, not just setup and go.

It’s Time to Move on From Legacy ERP

Modern aerospace work moves quickly. The reality is that legacy systems simply weren’t built for it. Cloud ERP offers better visibility, secure protection, and room to grow. If your current system is holding you back, it might be time to take the next step.

Key Takeaways:

• Legacy ERP systems come with high long-term costs and hidden labor burdens.
• Compliance and cybersecurity standards are changing, and old systems often can’t keep up.
• Manual workarounds and outdated tools slow down teams and limit visibility.
• Falling behind on tech could mean losing out on contracts or market share.
• Cloud ERP gives aerospace companies the tools to grow, adapt, and meet industry demands.

Action Items:

• Review how much time and money your team spends maintaining your current ERP.
• Check if your system meets current compliance and cybersecurity standards.
• Talk to your team about where they still rely on manual workarounds.
• Explore cloud ERP options designed for aerospace manufacturers.
• Look into WM Synergy’s FedRAMP-certified solution and hands-on consulting approach.

Connect with WM Synergy to talk about your ERP goals and begin building a system that fits the future of aerospace manufacturing.

Works Cited

What Are the Hidden Costs of Maintaining Legacy Systems?

The Hidden Costs of Legacy Software: Why It’s Time to Take Over

Aviation Sector Sees 600% Year-On-Year Increase in Cyberattacks

Optimizing Aerospace Supply Chain with AI and Big Data