The situation
The agency operates a global supply chain across 26 distribution centers, each processing between 200 and 5,000 or more daily transactions. Despite the migration from a legacy distribution system to a modern WMS and investment in 5G Smart Warehouse initiatives, the agency continues to face persistent asset visibility challenges that drive readiness shortfalls and unnecessary sustainment costs. High-value items — aircraft wings, engines, and avionics assemblies worth $500,000 or more — are routinely misplaced due to fragmented data systems. The consequence: AOG assets require additional maintenance to return to service, maintainers resort to cannibalizing other aircraft for working parts, and excess inventory accumulates while operational units face stockouts.
The aircraft sustainment program crystallizes the stakes. A 2025 GAO report found that the program cost increased by $163 billion — a 40% increase — over ten years, and that supply chain visibility initiatives were still in early stages with unclear implementation timelines. The GAO issued five open recommendations, including the establishment of a comprehensive mechanism to track aircraft configurations and the expanded use of digital twins. The report concluded that without action, the program risks failing to meet the warfighter’s needs.
A GAO assessment determined there was a need for a proven technology platform to execute on that mandate.
The solution
The PolyPhaze Knowledge Fabric™ connects WMS, ERP, RFID feeds, maintenance systems, and OEM supplier portals into a single governed intelligence layer without requiring data migration or system replacement. Entity resolution establishes one canonical, Trust-Scored record for every serialized asset across all connected systems — every distribution center, every depot, every field location. Every RFID read, every movement event, every maintenance action becomes a logged entry in the asset’s Serialized Inventory: a continuously-updated digital twin of each component’s location, condition, ownership, and readiness impact.
The Asset Twin capability builds the per-tail-number digital model of the fleet on that trusted foundation — each aircraft’s as-fielded configuration, maintenance history, and modification status reflected in the demand forecast. The GAO has identified this exact capability as a critical gap and an open recommendation. PolyPhaze has demonstrated it in production on operations through the Sustainment Office, and on other programs.
The Optimize capability runs demand forecasting, obsolescence prediction, and depot throughput analysis against the governed data. Experience-Based Learning updates continuously from live operational events, without retraining, so the demand forecast improves with every maintenance action and every RFID event. Zero Trust ABAC security is embedded at the data product level: classification travels with the data, enabling secure sharing across the organization, the services, OEMs, and partner nations without a centralized authorization server and without overexposure.