CASE STUDY | AEROSPACE

Hexcel Modernization Reduces Downtime by 80%

How System Integrator EOSYS helped carbon fiber and matrix manufacturer reduce downtime and upgrade legacy technology.

EOSYS creates value for our customers by delivering innovative technical solutions to automate, monitor, and secure their industrial systems, while anticipating future challenges they may face. Because we are an employee-owned company, our team members are personally invested in the success of each customer, recognizing its impact on the long-term success of EOSYS.

As a leading producer of carbon fiber reinforcements and resin systems, and the world leader in honeycomb manufacturing for the commercial aerospace industry, Hexcel is the strength within hundreds of products offered in multiple markets across the globe.

Chase Davis

Director of Technology, EOSYS

Bryce Wengren

Capital Project Manager, Hexcel

Challenge

Frequent encoder failures leading to $70,000 loss per downtime incident
Aging technology in a legacy manufacturing environment
Need for a strategic partner to provide expert guidance while respecting customer’s goals and vision

Solution

Result

Significantly reduced unplanned maintenance downtime, from 2% to 0.4%
Helped reduce encoder failures
Enhanced system reliability
Established a corporate-wide standard for modernization, now expanding globally

Challenge

A Need for Reduced Downtime and Strategic Modernization

Hexcel, a manufacturer with a long history of production, was facing equipment failures on its manufacturing lines. Frequent encoder failures on motor systems were causing unplanned downtime, with each instance resulting in a $70,000 loss and costing $7,000 per hour in lost productivity. Plant management needed a solution that would modernize aging technology, minimize costly downtime, and improve overall reliability—without disrupting long-standing processes or alienating experienced operators who had been with the company for decades.

Previously, Hexcel spoke with partners who either executed their requests without adding strategic value or imposed methodologies that didn’t fit their specific needs. They needed a partner that could provide expert guidance while also being receptive to their vision, specific goals, and operational requirements.

Solution

Incremental Approach to Modernization

Hexcel turned to EOSYS, a Platinum-level system integrator in the Rockwell Automation PartnerNetwork™. Together, Hexcel and EOSYS took a deliberate, step-by-step approach to modernization with each change driven by data and built on previous wins. They began by analyzing the root cause of the equipment failures and proposing a solution using permanent magnet motors—an approach that had been effective in Hexcel’s Decatur, Alabama, facility. To ease the transition, EOSYS initially kept encoders in place to provide Hexcel operators with peace of mind the motors were functioning properly.

The first phase of the project focused on one smaller manufacturing line at Hexcel’s Salt Lake City facility. This line, installed in 1976, featured a patchwork of outdated technologies. By converting it to AC drives and implementing permanent magnet motors, Hexcel and EOSYS achieved a quick and successful modernization.

With confidence from this early success, the team moved on to a more complex line with 30 motors. This larger line presented a new set of challenges, including overcurrent issues and non-standard motor specifications. To resolve these issues, Hexcel and EOSYS adjusted their approach, eventually transitioning to an open-loop induction motor system that maintained precision without requiring encoders.

By continuously refining their strategy and using each success as a proof point, Hexcel and EOSYS expanded their efforts to two additional lines, applying lessons learned. Specifically, they transitioned control systems from ControlNet to EtherNet/IP™ products to further system reliability and communication protocols. They also deployed PowerFlex® 755TS VFDs with embedded Ethernet/IP, positioning Hexcel to leverage advanced analytics, predictive maintenance, and anomaly detection technologies to drive even greater efficiency in the future.

By version 4.0, Hexcel and EOSYS had developed a solution that worked so well it was established as a standardized model for modernization and rolled out across Hexcel’s remaining Salt Lake City lines. Later, the solution was adopted by their France facility, with plans for further expansion into Spain.

Result

80% Downtime Reduction and a Scalable Model for the Future

By implementing a thoughtful, step-by-step modernization approach, Hexcel brought encoder failures—a major source of downtime—to zero. They reduced unplanned maintenance downtime from 2% to just 0.4%, an improvement that translated to substantial cost savings and increased operational efficiency.

This success was possible because EOSYS provided more than just technical expertise—they acted as a true strategic partner.

"We were looking for a partner in solving problems. EOSYS helped us find the best approach."

Bryce Wengren - Capital Project Manager, Hexcel

Chase Davis, Director of Technology at EOSYS adds, “When we were brought in, we had an inkling that there was a better way. But you don’t just want to rip out everything, start from scratch, and invalidate the product. We wanted to get some easy wins quickly and build upon that momentum.”

Rather than simply executing tasks or enforcing a methodology that ignored the decades of expertise of Hexcel workers, they worked collaboratively, balancing expert guidance with flexibility so that each decision aligned with Hexcel’s long-term vision and operational realities.

Published April 30, 2025